5HP500-590 4139 - 751 - 627d

REPAIR MANUAL
005380
005380
HP 500 / HP 590
NBS
Stage 3
4139 751 627d
Subject to modification
Copyright by ZF
These repair instructions are protected by copyright. Any reproduction and dissemination in whatever
form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or
electronic reproduction or as a storage in data-processing equipment or data networks without approval
by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.
Printed in Germany
Edition: 2000-02
4139 751 627d

Ecomat HP 500 / HP 590 Contents
Chapter Contents Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Important work safety notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Sectional view of transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -11
Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Table of springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1. Placing transmission in assembly stand and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 Placing transmission in assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.2 Removing transmission from assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2. Removal, installation, disassembly and assembly of retarder accumulator . . . . . . . . . . . . 2-4

2.1 Removal of retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Removal of retarder accumulator from side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Installation of retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Installation of retarder accumulator on side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Disassembly of retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6 Disassembly of retarder accumulator for side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . 2-9
2.7 Assembly of retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.8 Assembly of retarder accumulator for side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 2-11
3. Removal, installation, disassembly and assembly of oil cooler . . . . . . . . . . . . . . . . . . . . . . 2-12

3.1 Removal of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
3.2 Removal of side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
3.3 Installation of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
3.4 Installation of side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
3.5 Disassembly of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
4. Disassembly and assembly of connecting components for side-mounted oil cooler . . . . . 2-19
4.1 Disassembly of connecting components for side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . 2-19
4.2 Assembly of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
4.3 Assembly of connecting components for side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . 2-22
5. Removal, installation, disassembly and assembly of converter . . . . . . . . . . . . . . . . . . . . . . 2-23

5.1 Removal of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
5.2 Installation of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
5.2.1 Measurement of converter end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
5.2.2 Measurement of installation dimensions of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
5.3 Disassembly of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
5.3.1 Disassembly of stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
5.3.2 Assembly of stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
5.3.3 Disassembly of turbine wheel and circuit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
5.3.4 Assembly of circuit cover and turbine wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
5.4 Assembly of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
5.4.1 Measurement and setting of end play for axial bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
5.4.1.1 New O-ring seal on HP 590 converter (ZFW 380-30) fitted during repairs . . . . . . . . . . . . . . . . 2-52
5.4.2 Check for converter leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
1-1
Contents Ecomat HP 500 / HP 590
6. Removal and installation of cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

6.1 Removal of cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
6.2 Installation of cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
7. Removal and installation of oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

7.1 Removal of oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
7.2 Installation of oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
8. Removal and installation of inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

8.1 Removal of inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
8.2 Installation of inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
9. Removal, installation, disassembly and assembly of hydraulic transmission control unit 2-67
9.1 Removal of hydraulic transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
9.1.1 Retrofitting impurity collecting magnets on hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . 2-68
9.2 Installation of hydraulic transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
9.3 Disassembly of hydraulic transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
9.3.1 Disassembly of throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
9.3.2 Assembly of throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
9.3.3 Disassembly of valve block for brake “F”, lock-up clutch and clutches “C” and “A” . . . . . . . 2-80
9.3.4 Disassembly of valve block for clutch “B” and brakes “E”, “D” and “G” . . . . . . . . . . . . . . . . 2-84
9.4 Assembly of hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
9.4.1 Assembly of valve block for brake “F”, lock-up clutch and clutches “C” and “A” . . . . . . . . . 2-89
9.4.2 Assembly of valve block for clutch “B” and brakes “E”, “D” and “G” . . . . . . . . . . . . . . . . . . 2-95
10. Removal and installation of retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

10.1 Removal of retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
10.2 Installation of retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
11. Removal, installation, disassembly and assembly of output cover . . . . . . . . . . . . . . . . . . . 2-108

11.1 Removal of output cover/inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
11.1.1 Installation of inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
11.2 Installation of output cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115
11.2.1 Measurement of end play on sun gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
11.3 Disassembly of output cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
11.4 Assembly of output cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-126
11.4.1 Adjustment of tapered roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
11.4.2 Setting of disc play for brake “F” (NBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136
1-2
Ecomat HP 500 / HP 590 Contents
12. Removal and installation of mechanical transmission section . . . . . . . . . . . . . . . . . . . . . . 2-141

12.1 Removal of mechanical transmission section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
12.1.1 Disassembly of planetary carrier II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144
12.1.2 Assembly of planetary carrier II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147
12.1.3 Disassembly of planetary carrier I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-151
12.1.4 Assembly of planetary carrier I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
12.1.5 Removal of sun gear from disc carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159
12.1.6 Installation of sun gear in disc carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159
12.2 Installation of mechanical transmission section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-163
12.2.1 Measurement and adjustment of inductive sensor ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-172
13. Removal, installation, disassembly and assembly of control unit . . . . . . . . . . . . . . . . . . . . 2-173

13.1 Removal of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-173
13.2 Installation of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-175
13.3 Disassembly of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-178
13.3.1 Disassembly of control insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-179
13.3.2 Assembly of control insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-191
13.3.3 Disassembly of clutch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-204
13.3.4 Assembly of clutch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-212
13.3.5 Clutch carrier leakage test and functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-225
13.4 Assembly of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-227
14. Removal and installation of D brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-230

14.1 Removal of D brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-230
14.2 Installation of D brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-232
1-3
Preface Ecomat HP 500 / HP 590
This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with the standard ZF product in accordance with the state of development on the date of
issue.
However, due to continuing development of the product, repair work might require work practices and test or
adjustment data which are not contained in this manual. We therefore recommend that work done on your ZF
product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on
a regular basis at our After-Sales Service training courses.
Service points equipped by ZF Friedrichshafen AG all over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. specialized tools
3. Genuine ZF spares, to our latest specifications
All work performed in these service points is carried out conscientiously and with care.
Repair work carried out at ZF service points is guaranteed in accordance with the prevailing contractual
conditions.
Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together
with follow-on costs caused by such work, is excluded from the contractual warranty agreement. This also applies
where genuine ZF spares have not been used.
ZF FRIEDRICHSHAFEN AG
Friedrichshafen Division
After-Sales Service
1-4
Ecomat HP 500 / HP 590 General
General
The service manual deals with the ZF Ecomat HP500/HP590 4- and 5- speed version, including optional “Neutral
at Bus Stop” (NBS) function. The manual lists all the procedures required for disassembly and subsequent
assembly of the transmission.
When repairing the transmission, take extreme care with regard to cleanliness and workmanship. The transmission
should only be disassembled to replace damaged parts.
Cover and housing parts that are in contact with gaskets must be loosened by tapping with a plastic mallet once the
nuts or bolts have been loosened. Use suitable extraction devices to remove parts such as bearings, bearing races
etc., which are tightly fitted to the shafts.
Perform disassembly and assembly work in a clean working environment. Use the special tools which have been
specifically developed. Before reinstalling parts, clean the contact surfaces of the housing and cover to remove any
gasket residue. Remove any burrs or similar areas of roughness using an oil stone. Wash housings and the cover
plate with a suitable cleaning agent, paying particular attention to corners and angles. Renew damaged and severely
worn components. Expert personnel shall assess whether parts subject to normal wear, such as bearings, thrust
washers etc., should be reinstalled. Always renew parts such as sealing rings, fixing plates and split pins etc. Also
renew shaft sealing rings which have worn or torn sealing lips. Take particular care to ensure that no metal shavings
or other foreign bodies are left inside the housing. Check lubrication oil bores and grooves to ensure they are
perfectly clear.
Lubricate all bearings with oil before installing them.
NOTE: Only use an industrial oven or hot-air blower to heat up parts such as bearings, housings, etc.
CAUTION
When reassembling the transmission, observe the torques and adjustment data listed in the intructions exactly.
Unless otherwise stated, tighten bolts and nuts as listed in the standard table contained in this manual. Do not use
liquid sealant compounds in this transmission, because they can cause malfunctions in the control section.
Never use molycote grease.
Never wash lined disks. Only clean discs using a leather cloth.
! DANGER
Observe the manufacturer’s instructions when using cleaning agents.
1-5
General Ecomat HP 500 / HP 590
Layout of the service manual
The layout of this manual corresponds to the order of working steps required to completely strip down a
transmission that has already been removed. Each section describes the removal and installation of a subassembly
and gives details of how to disassemble and reassemble that subassembly.
The start of each section also gives the preliminary work which must be performed if only the subassembly being
discussed in that particular section needs to be removed.
A list of special tools required for carrying out repair work are listed under the section headed „Special Tools“.
1-6
General Ecomat HP 500 / HP 590
Important work safety notice:
Companies who repair ZF units are responsible for their own work safety.
To avoid injury to personnel and damage to products, all safety regulations and legal requirements which
apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize
themselves with these regulations.
Personnel required to carry out repairs on these ZF products must receive appropriate training in advance. It isnce.
It is the responsibility of each company to ensure that their repair staff is properly trained.
The following safety instructions appear in this manual:
NOTE: Refers to special processes, techniques, data, use

of auxiliary equipment, etc.
CAUTION This is used when incorrect, unprofessional

working practices could damage the product.
! DANGER This is used when lack of care could lead to

personal injury or death.
NOTE: Read this manual carefully before starting any tests or repair work.
CAUTION
Pictures, drawings and components do not always represent the original object, but are used to illustrate working
procedures.
Pictures, drawings and components are not to scale and no information about size and weight should be inferred
(even within a complete illustration).
Always follow the working steps as described in the text.
NOTE: After completion of repair work and testing, skilled staff must satisfy themselves that the product is
functioning correctly.
1-7
Sectional view of transmission Ecomat HP 500 / HP 590
Sectional view of the ECOMAT 4-speed version
1 2 4 5 6 7 9 10 11 12 13
004 250
25 24 23 22 21 20 19 18 17 16 15 14
004250
1 Input 15 Brake “F”

2 Cover plate 16 Brake “E”
4 Control insert 17 Brake “D”
5 Oil feed flange 18 Control unit
6 Clutch “A” 19 Inductive sensor “turbine”
7 Clutch “B” 20 Oil pan
9 Housing 21 Retarder
10 Planetary gear set I 22 Primary pump
11 Planetary gear set II 23 Torque converter
12 Planetary gear set III 24 Lock-up clutch “WK”
13 Output 25 Turbine shaft
14 Inductive sensor “output”
1-8
Ecomat HP 500 / HP 590 Sectional view of transmission
Sectional view of the ECOMAT 5-speed version
1 2 3 4 5 6 7 8 9 10 11 12 13
004 251
25 24 23 22 21 20 19 18 17 16 15 14
004251
1 Input 14 Inductive sensor “output”

2 Cover plate 15 Brake “F”
3 Drive gears for PTO 16 Brake “E”
4 Control insert 17 Brake “D”
5 Oil feed flange 18 Control unit
6 Clutch “A” 19 Inductive sensor “turbine”
7 Clutch “B” 20 Oil pan
8 Clutch “C” 21 Retarder
9 Housing 22 Primary pump
10 Planetary gear set I 23 Torque converter
11 Planetary gear set II 24 Lock-up clutch “WK”
12 Planetary gear set III 25 Turbine shaft
13 Output
1-9
1-10
Tightening torques Ecomat HP 500 / HP 590
Tightening torques for bolts and nuts from ZFN 148
This Standard applies for bolts as per DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and nuts as per DIN 934.
This Standard contains data on tightening torques (MA) for bolts in strength categories 8.8, 10.9 and 12.9 and nuts
in strength categories 8, 10 and 12.
Surface condition of bolts: heat-treated blackened finish and oiled; galvanized and oiled; galvanized, chrome-plated
and oiled.
Tighten screws using a calibrated signal or pointer-type torque wrench.
Metric coarse pitch thread Metric fine pitch thread
Size Tightening torque Size Tightening torque

MA (Nm) for MA (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M 4 2.8 4.1 4.8 M 8x1 24 36 43

M 5 5.5 8.1 9.5 M 9x1 36 53 62
M 6 9.5 14 16.5 M 10 x 1 52 76 89
M 7 15 23 28 M 10 x 1.25 49 72 84
M 8 23 34 40 M 12 x 1.25 87 125 150
M 10 46 68 79 M 12 x 1.5 83 122 145
M 12 79 115 135 M 14 x 1.5 135 200 235

M 14 125 185 215 M 16 x 1.5 205 300 360
M 16 195 280 330 M 18 x 1.5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490

M 20 390 560 650 M 20 x 1.5 430 620 720
M 22 530 750 880 M 22 x 1.5 580 820 960
M 24 670 960 1100 M 24 x 1.5 760 1100 1250

M 27 1000 1400 1650 M 24 x 2 730 1050 1200
M 30 1350 1900 2250 M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800

M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
Edition: August 1991
1-11
Adjustment data Ecomat HP 500 / HP 590
Description Data Measuring device Remarks
Converter
01. Installation dimension of 2.81 ± 0.02" Depth gauge Installation dimension

converter (depending on (71.25 ± 0.5 mm) measured from flange face on
version) 3.01 ± 0.02" converter to flange face on
(77.00 ± 0.5 mm) transmission housing.
3.20 ± 0.02" Installation dimension can be
(81.25 ± 0.5 mm) adjusted by placing one or
3.40 ± 0.02" more spacer rings on stator
(86.25 ± 0.5 mm) quill shaft.
02. Converter end play be- 0.01 to 0.016" Depth gauge End play can be adjusted by
tween face end of inner race on (0.3 to 0.4 mm) adding shims to face end of
converter freewheel and spacer turbine shaft.
ring on stator quill shaft.
03. Disc play of lock-up clutch 0.02 to 0.043" Feeler gauge Measure disc play between
in converter. (0.5 to 1.1 mm) end disc and inner disc
04. End play of axial bearing 0.004 to 0.01" Measurement bars and Adjust by fitting spacer discs
in converter (0.1 to 0.3 mm) depth gauge between housing and turbine
flange
05. Maximum pressure for 36 + 7 psi Forcing device Check converter underwater
converter leak test (2.5 +0.5 bar) 1X56 137 129, using air
compressed air unit
1X56 137 130 and
water container
06. Tightening torque of cap Torque wrench

screws on converter
HP 500 (M8) = 26 ft-lbs (35 Nm)
HP 590 (M10) = 44 ft-lbs (60 Nm)
07. Tightening torque of M16 133 to 140 ft-lbs Torque wrench and Lock the converter using
cap screw in turbine shaft (180 to 190 Nm) supporting fixture brace bracket 1X56 137 658
1X56 137 158
08. Tightening torque of 140 to 155 ft-lbs Torque wrench Insert new copper sealing
M33x2 screw plug in converter (190 to 210 Nm) washer.
Lock the converter using
brace bracket 1X56 137 658
1-12
Ecomat HP 500 / HP 590 Adjustment data
Output
09. Specified distance between 0.02 to 0.027" Depth gauge, measure- Adjust distance using shims.
contact face of inductive (0.5 to 0.7 mm) ment rule 1P01 137 833
sensor (in output cover) and
face of toothed disc (impulse
sensor)
10. End play of speedo shaft 0.004 to 0.01" Depth gauge Can also be checked by hand
(0.1 to 0.3 mm) (touch)
11. Tooth backlash of speedo 0.004 to 0.008 Experience Backlash is fixed, check by
shaft (0.1 to 0.2 mm) hand (touch)
12. Installation dimension of 0.60 -0.04" Depth gauge Adjust installation dimension
shaft seal in output cover (15 -1 mm) from end of tapered roller
bearing inner race to end face
of sealing ring using inserter
1X56 136 824. Double-check.
13. Pre-load of taper roller 0.002 to 0.006" Setting device Set to 1.3 ft-lbs to 4.7 ft-lbs
bearing in output cover when (0.05 to 0.15 mm) 1P01 136 816, dial (1.8 - 6.4 Nm) drag torque of
cold (approx. 20 ºC) preload gauge and tension taper roller bearing. The
balance adjustment is made using
spacing washers. Difference
1.8 to 6.4 Nm between speedometer worm
Drag torque and setting ring = dimension
“C”.
Thickness "S" of spacing
washer =
C + 0.002" (0.05 mm).
14. Total end play between sun 0.02 to 0.03" Measurement bars and Fit shims to output to obtain
gear and output (0.6 to 0,8 mm) depth gauge correct setting.
15. Installation dimension of 0.10 + 0.04" Depth gauge Measured from thrust face of
needle bearing in planetary (2.5 +1 mm) shim to edge of needle
carrier III bearing. Use rod
1X56 137 101 to set the
correct installation
dimension.
16. End play of planetary gears 0.02 to 0.05" Feeler gauge End play is fixed, double-
in planetary carrier III (0.5 to 1.2 mm) check
1-13
17. Tightening torque of M6 3.7 to 5.6 ft-lbs Torque wrench

stud bolts on output cover (5 to 7.5 Nm)
18. Tightening torque of M6 5 ft-lbs Torque wrench

hex nuts on output cover 6 Nm
19. Tightening torque of max. 37 ft-lbs Torque wrench Do not exceed stated value
inductive sensor (output speed) (50 Nm)
20. Tightening torque of M12 44 ft-lbs Torque wrench Secure with tab washer.
hex bolts on output flange (60 Nm) Use punch 1X56 136 471
21. Tightening torque of approx. 88 ft-lbs Torque wrench Fit new copper sealing
speedo connection piece (120 Nm) washer
Control insert
22. Separate check of primary approx. 18.5 gal/min Measuring container Measured at pump speed of
pump delivery volume (60 l/min) and stopwatch n = 1500 rpm. SAE 10 W oil
(theoretical value) at 80°C. Primary pump is a
complete assembly.
23. Clearance between spring 0.06 + 0.02" Vernier callipers Adjust by removing or
guide and guide bolt of stator (1.6 +0.5 mm) installing cup springs used for
ring installation. Measure with
cup springs in unloaded
condition.
Clutch carrier
24. Test pressure for pistons of 36 + 7 psi Insertion bush Pressure test for leakage:
clutches “A”, “B” and “C”. (2.5 +0.5 bar) 1X56 137 128, Pressure drop of 36 + 7 psi to
Compressed air unit 20 psi (2.5 + 0.5 bar to 1.4
1X56 137 130 bar) after cut-off = 10 sec.
25. Disc play of clutch “A” 0.13 to 0.15" Depth gauge Deviations can be corrected
(3.2 to 3.7 mm) by installing steel discs of
differing thicknesses or a
different “A” piston
1-14
26. Disc play of clutch “B” 0.06 to 0.082" Feeler gauge Measure by inserting feeler
(1.6 to 2.1 mm) gauge between end disc and
(HP 500) outer disc. Correct deviations
0.08 to 0.10" by installing steel discs of
(2.0 to 2.5 mm) differing thicknesses or a
(HP 590) different “B” piston
27. Disc play of clutch “C” 0.05 to 0.06" Feeler gauge Measure by inserting feeler
(1.2 to 1.7 mm) gauge between reverse gear
(HP 500) „pot“ and outer disc. Correct
0.06 to 0.082" deviations by installing steel
(1.6 to 2.1 mm) discs of differing thicknesses
(HP 590) or a different “C” piston
28. Run-out of inductive sensor + 0.008" (+ 0.2 mm) Dial gauge Measure from the raised point
ring when installed on the inductive sensor ring.
Correct by tapping lightly
with a plastic mallet.
29. Tightening torque of M8 26 ft-lbs (35 Nm) Torque wrench

hex nuts on rotor (retarder)
Mechanical transmission
section
in planetary carrier I (0.5 to 1.2 mm) check
31. Disk play of brake “D” 0.06 to 0.082" Feeler gauge Measure by inserting feeler
(1.6 to 2.1 mm) gauge between end disc and
outer disc. Correct deviations
by adding or removing outer
discs.
32. Installation dimension of 0.16 + 0.04" Depth gauge Measured from thrust face of
needle bearing in input shaft (4 +1 mm) thrust disc to edge of needle
bearing. If rod 1X56 137 101
is used, the installation
dimension will be correct.
in planetary carrier III (0.5 to 1.2 mm) check
1-15
34. Disc play of brake “E” 0.10 to 0.12" Feeler gauge Measure by inserting feeler
(2.5 to 3.0 mm) gauge between sealing ring
(HP 500) and outer disc. Correct
0.12 to 0.14" deviations by adding outer
(3.0 to 3.5 mm) discs
(HP 590)
35. Disc play of brake “F” 0.13 to 0.15" Depth gauge Correct deviations by
(3.2 to 3.7 mm) inserting discs of differing
thicknesses or a different “F”
piston
Hydraulic control unit
36. Specific clearance between 0.02 to 0.03" Depth gauge, Adjust clearance using shims
contact face of inductive (0.6 to 0.8 mm) measurement rule
sensor (in duct plate) and 1P01 137 833
raised areas around rim of
inductive sensor ring (impulse
sensor)
37. Tightening torque of max. 37 ft-lbs Torque wrench Do not exceed stated value
inductive sensor (turbine (50 Nm)
speed)
38. Tightening torque of 60 to 74 ft-lbs Torque wrench

M42x2 screw plug (tapered in (80 to 100 Nm)
duct plate)
Retarder accumulator
39. Tightening torque of M8 5.6 to 7.4 ft-lbs Torque wrench Only replace stud bolts with
stud bolts on rear cover of (7.5 to 10 Nm) new ones if damaged
retarder accumulator
40. Tightening torque of M8 11 ft-lbs (15 Nm) Torque wrench Fit washers
lock nuts on retarder
accumulator cover
41. Tightening torque of 18 ft-lbs (25 Nm) Torque wrench Fit new copper sealing
M12x1.5 screw plug in washer
solenoid valve
1-16
Other transmission data
42. Installation dimension of 1.57 + 0.04" Depth gauge Measurement from sealing
oil filler pipe (40 +1.0 mm) face of transmission housing
(oil pan connection) to end of
filler pipe.
(Use sealing tape on thread)
43. Tightening torque of approx. 60 ft-lbs Experience

M30x1.5 slotted nut on oil (80 Nm)
filler pipe
44. Tightening torque of 37 ft-lbs Torque wrench Fit new copper sealing
M22x1.5 oil drain plug in oil (50 Nm) washer
pan
45. Tightening torque of 9 ft-lbs Torque wrench Fit new copper sealing
M10x1 screw plug on pressure (12 Nm) washer
measuring ports
46. Tightening torque of approx. 15 ft-lbs Torque wrench Fit new copper sealing
M10x1 union screws in cover (20 Nm) washer
plate
1-17
Table of springs Ecomat HP 500 / HP 590
External
Order number Installation position No. of coils Wire dia spring dia Length (untensioned)
0732 041 934 Control insert - 13.50 0.055" 0.4" 2.21"

Stator ring (1.40 mm) (16.35 mm) (56.20 mm)
0732 041 718 Control insert - 14.50 0.095" 0.57" 2.42"

Main pressure valve P1 (2.40 mm) (14.58 mm) (61.60 mm)
0732 041 719 Control insert - 10.50 0.138" 0.90" 2.57"

Main pressure valve P1 (3.50 mm) (22.84 mm) (65.30 mm)
0732 042 113 Control insert - 17.50 0.110" 0.61" 2.93"

Main press. valve P2/P3.1 (2.80 mm) (15.66 mm) (74,56 mm)
0732 042 114 Control insert - 11.50 0.118" 0.90" 2.79"

Main press. valve P2/P3.1 (3.00 mm) (22.9 mm) (71.14 mm)
0732 041 125 Control insert - 4.50 0.098" 0.91" 0.89"

Lubrication pressure valve (2.50 mm) (22.94 mm) (22.70 mm)
0732 041 654 Control insert - Converter 10.50 0.110" 0.72" 1.90"
pressure back-up valve (2.80 mm) (18.40 mm) (48.50 mm)
0732 040 786 Control insert - 14.50 0.098" 0.69" 2.65"

Cooler change-over valve (2.50 mm) (17.54 mm) (67.40 mm)
0732 041 269 Clutch carrier 28.50 0.070" 0.45" 3.43"

B clutch (1.80 mm) (11.50 mm) (87.20 mm)
0732 041 373 Gearshift control - 27.50 0.035" 0.21" 1.51"

Valve blocks (0.90 mm) (5.40 mm) (38.40 mm)





1-18
Ecomat HP 500 / HP 590 Table of springs
External
Order number Installation position No. of coils Wire dia spring dia Length (untensioned)



Pre-control valve (2.25 mm) (11.81 mm) (63.40 mm)
0732 041 098 Retarder 12.50 0.055" 0.43" 1.43"

control valve (1.40 mm) (11.16 mm) (36.40 mm)
0732 041 142 Retarder 31.50 0.049" 0.36" 2.85"

control valve (1.25 mm) (9.21 mm) (72.50 mm)
0732 041 322 Retarder 9.50 0.098" 0.58" 2.31"-0.01

control valve (2.50 mm) (14.86 mm) (58.90 -0.03 mm)
0732 041 847 Disc brake “D” 10.50 0.062" 0.39" 1.09"
(1.60 mm) (10.10 mm) (27.80 mm)
0732 041 409 Disc brakes “E” and “F” 50.50 0.062" 0.33" 4.84"
(1.60 mm) (8.60 mm) (123.00 mm)
0732 042 334 Disc brakes “E” and “F” 22.50 0.05" 0.35" 2.44"
with "NBS" (1.50 mm) (8.96 mm) (62.36 mm)
0732 041 421 Clutch carrier - 24.50 0.07" 0.45" 3.10"

Reverse gear „pot“ (2.00 mm) (11.60 mm) (79.10 mm)
1-19
Special tools Ecomat HP 500 / HP 590
Fig. Illustration Order No. Application Qty. Remarks

No.
1X56 097 775 2
Assembly hooks
1 for lifting planetary carrier out of
housing
1X56 100 632 1
Adapter with taper

2 for shaft sealing ring (10 x 15 x 3) in
speedo connection piece
1X56 122 205 1
Internal extractor
3 for needle bearing (18 x 24 x 16) in
planetary carrier II and in input shaft
(use with 1X56 122 227)
1X56 122 208 1
Internal extractor
4 for needle bearing (45 x 52 x 16)
(use with 1X56 122 227)
1X56 122 227 1
Counter bracket
5 use with internal extractors
1X56 122 205 and 1X56 122 208
1-20
Ecomat HP 500 / HP 590 Special tools

No.
1X56 122 306 1
Base tool
6 use with grip 1X56 136 706
1X56 122 322 1
Extractor
7 for grooved ball bearing
(0635 331 232) in control insert
1X56 124 659 1
Extractor plate
8 for bearing inner race on stator quill
shaft
1X56 126 464 1
Extractor
9 for speedo worm
1X56 136 260 1
Lifting device
10 for complete output
1-21

No.
1X56 136 471 1
Punch
11 for tab washer on output flange
1X56 136 513 (220V) Optional 1

1X56 137 575 (110V)
12 Hot-air blower
for heating various components
1X56 136 594 1
Adapter (LH)
13 for supporting the transmission (use
with assembly stand 1X56 137 450)
1X56 136 595 1
Adapter (RH)
14 for supporting the transmission (use
with assembly stand 1X56 137 450)
1X56 136 605 1
Punch
15 for shaft sealing ring
(125 x 150 x 10) behind torque
converter
1-22

No.
1X56 136 612 2
M8 Hook
16 for lifting control insert off clutch
carrier
1P01 137 833 1
Measurement rod
17 for measuring inductive sensor
clearance
1X56 136 706 1
Grip
18 for tapered roller bearing
(0635 370 006) on output
1X56 136 815 3
Extractor
19 for cover plate behind torque
converter
1P01 136 816 1
Adjustment device
20 for tapered roller bearing on output
1-23

No.
1X56 136 818 1
Support
21 for oil feed flange when fitting
control insert
1X56 136 820 1
Punch
22 for removal of bush in stator quill
shaft
1X56 136 821 2
M8 guide bolts
23 for installation of control insert and
primary pump
1X56 136 824 1
Inserter
24 for shaft sealing ring (90 x 125 x 10)
on output and bearing outer race in
output cover
1X56 136 862 1
Lifting device
25 for converter
1-24

No.
1X56 137 101 1
Rod
planetary carrier III and input shaft
1X56 137 103 1
Rod
clutch body hub
1X56 137 104 1
Pressure piece
28 for pulling off grooved ball bearing
in control insert
(use with 1X56 122 322)
1X56 137 105 1
Pressure piece
29 for inserting securing rings in front
of “A” piston cup springs
1X56 137 107 1
Device
30 107
for inserting spacer rings
6 137
1X5
4139 310 018 in control insert
1-25

No.
1X56 137 108 1
Clamping device
31 for removal and installation of main
pressure valve and lubricating
pressure valve and/or converter
pressure back-up valve in control
insert
1X56 137 109 1
Rod
32 for separating clutch carrier from
control insert
1X56 137 126 1
Lifting device
33 for Ecomat transmissions
1X56 137 127 1
Clamping device
34 for inductive sensor ring
1X56 137 128 1
Insertion bush
35 for leakage check of clutches in
clutch carrier
1-26

No.
1X56 137 129 1
Forcing device
36 for converter leak test
1X56 137 130 1
Compressed air unit

37 for leak test of converter and clutch
carrier. Use with insertion bush
1X56 137 128 and forcing device
1X56 137 129
1X56 137 151 1
Punch
38 for knocking in and peening the
pressure control unit orifices
1X56 137 152 2
Support
39 for stator bearing
1X56 137 153 2
Insert
40 for cleaning oil cooler
1-27

No.
1X56 137 156 1
Punch
41 for knocking out orifices
1X56 137 158 1
Holding device
42 for loosening and tightening M16
cap screw in converter
1P01 137 173 1
Plug gauge
43 range 0.03 to 0.12” (0.7 to 3.0 mm),
for measuring orifices
1X56 137 213 1
Lifting device
44 for turbine shaft
1X56 137 273 1
Internal hex head driver

45 for cap screws on control insert
1-28

No.
1X56 137 432 1
Extractor
46 for pressing off piston ring carrier
from stator quill shaft
1X56 137 450 1
Assembly stand
47 can be swivelled/pivoted
1X56 137 464 1
Support
48 for securing planetary gear pins
1X56 137 465 1
Punch
49 for closing in the planetary gear pins
of planetary carrier I
1X56 137 466 1
Punch
50 for closing in the planetary gear pins
of planetary carriers II and III
1-29

No.
1X56 137 658 1
Brace bracket
51 for loosening and tightening screw
plugs in converter
1X56 150 111 2
M6 threaded pin
52 for control unit
1P01 137 906 1
Adjustment device
53 for setting NBS (Neutral at bus stop)
1-30
“Make your own” auxiliary tools
Auxiliary punch for centring planetary gears
ø1
4139 333 041 4139 233 049 / 4139 333 667
ø1 0.9834 - 0.002” 1.1803 - 0.002”

24.98 - 0.05 mm 29.98 - 0.05 mm
ø2 0.5897 - 0.002” 0.7866 - 0.002”
L1
14.98 - 0.05 mm 19.98 - 0.05 mm
L1 3.15” 3.15”
80 mm 80 mm
L2
L2 0.315” 0.315”
ø2 8 mm 8 mm
1-31
Ecomat HP 500 / HP 590 Assembly stand
1 Placing transmission in assembly stand and

removing.
1.1 Placing transmission in assembly stand. 1
2
1 Secure adapters (1/2) on the transmission assembly
stand.
2 Tighten M10 hex nuts and bolts;

Tightening torque: 34 ft-lbs (46 Nm). 3 4
3 Unscrew cap screws (4).
4 Set distance “A” to approx. 21.65” (550 mm) by

moving the center cross-beam. 5
4
5 Tighten cap screws (4).

000786
6 Attach lifting device 1X56 137 126 to output cover

(1).
7 Screw in four M16x1.5 hex bolts;

Tightening torque: 81 ft-lbs (110 Nm).
008380
8 Unscrew shackle (1) and insert it and ring (2) into

the correct bore. Tighten the shackle.
! DANGER
Insert the shackle carefully.
See the instruction plate on the lifting device.
9 Attach ring (2) to the crane hook. Move the

transmission over the assembly stand, center it
between the adapters and lower it into the assembly
stand.
008381
2-1
Assembly stand Ecomat HP 500 / HP 590
10 Tighten the RH adapter on the transmission. Screw

in hex bolts (1);
Tightening torque: 166.4 ft-lbs (225 Nm).
008382
11 Pivot the LH adapter (1) upwards and fasten it to

the transmission with M16x1.5 hex bolts;
12 Remove the crane hooks and the lifting device.
13 Release the assembly stand and pivot the

transmission into the desired position.
! DANGER
Avoid knocking or hitting the transmission
outside of its axis of rotation.
008383
! DANGER
Stand clear when pivoting the transmission.
Lock the assembly stand with a pin after
pivoting the transmission. Secure pin (1) with
lock screw (2).
008384
2-2
Ecomat HP 500 / HP 590 Assembly stand
1.2 Removing transmission from assembly stand.
1 Place lifting device 1X156 137 126 against the

output cover. Screw in four hex bolts;
Tightening torque: 81 ft-lbs (110 Nm)
008385
2 Attach a crane hook to ring (1).
3 Using lifting equipment, lift until ring (1) is under

slight tension.
! DANGER
Do not lift the assembly stand.
008386
! DANGER
Secure the LH adapter to stop it swinging down.
4 Unscrew the hex bolts from the adapters.
! DANGER
The transmission may drop slightly - take care
not to get trapped.
5 Remove the transmission from the assembly stand.
008387
2-3
Retarder accumulator Ecomat HP 500 / HP 590
2 Removal, installation, disassembly and assembly

of retarder accumulator.
2.1 Removal of retarder accumulator.
1 Unscrew and remove M8 hex bolts (1). Remove

solenoid valve (2) from the accumulator.
008388
2 Unscrew and remove M10 hex bolts (1) from the

output cover.
008389
3 Unscrew and remove M8 cap screws (1). Remove

the retarder accumulator from connection (2).
008390
2-4
Ecomat HP 500 / HP 590 Retarder accumulator
2.2 Removal of retarder accumulator from side-

mounted oil cooler. 1
1 Unscrew M8 hex bolts and remove solenoid valve 2

(2) with O-ring (3) from the accumulator. 3
001558
001558
2 Unscrew hex bolts (1) and remove retarder

3
accumulator (2) with gaskets (3) from oil cooler
(4). 4
3
1
001565
001565
2-5
2.3 Installation of retarder accumulator
1 Insert new O-ring (1) in the accumulator cover.
NOTE: Coat the O-ring with Vaseline.
008393
2 Push the retarder accumulator against the

connection. Fit one washer to each M8x2.5 cap
screw (1) and bolt the retarder accumulator onto the
connection;
008391
3 Fit a washer to each M10 hex bolt (1) and bolt the
bracket onto the output cover;
Tightening torque: 34 ft-lbs (46 Nm)).
NOTE: Ensure the accumulator is not placed under

tension due to the bracket. Use washers to correct if
necessary.
008392
2-6
4 Coat new O-ring (1) with Vaseline and insert it in

the solenoid valve.
008394
5 Hold solenoid valve (1) against the accumulator.
6 Fit one washer to each M8x55 hex bolt (2) and

screw them into the solenoid valve;
NOTE: Fit the solenoid valve with the electrical

connection pointing upwards (3).
008395
2.4 Installation of retarder accumulator on

side-mounted oil cooler. 7
6
1 Hold retarder accumulator (1) and gaskets (2) 3 5
against oil cooler (3).
1
2 Fit washers to six hex bolts (4) and screw on the oil
accumulator;
Tightening torque: 17 ft-lbs (23 Nm). 4
3 Coat new O-ring (5) with Vaseline and insert it into

the solenoid valve.
2
4 Hold solenoid valve (6) against the accumulator.
Screw it on using two hex bolts (7) and washers;
Tightening torque: 17 ft-lbs (23 Nm). 001573
001573
2-7
2.5 Disassembly of retarder accumulator.
1 Remove M8 lock nuts (1) and washers.
2 Remove connection plate (2).
008396
3 Remove rear cover (1).
4 Slide complete piston (2) out of tube (3).
008398
5 Use a suitable tool to remove grooved rings (1)

from piston.
6 Remove piston guide ring (2) from piston.
008397
2-8
7 If any of the threaded pins (1) are damaged, use a

bolt drawer or bolt punch to remove it from the rear
cover.
8 Screw in a new threaded pin if required;

Tightening torque: 5.6 to 7.4 ft-lbs (7.5 to 10 Nm).
008399
2.6 Disassembly of retarder accumulator for

side-mounted oil cooler.
1
1 Disassemble the retarder accumulator as described
in 2.5.
NOTE: The retarder accumulator connection plates (1)

and (2) are different.
001574
001574
2-9
2.7 Assembly of retarder accumulator.
NOTE: Clean all parts thoroughly before assembly.

Always renew slotted rings, O-rings, piston guide rings,
cap collars etc.
1 Insert new slotted rings (1) into the piston ring

groove.
2 Insert new piston guide ring (2) onto the piston.
CAUTION
Insert slotted rings with their open side facing outwards.
008400
3 Coat the outside of the piston and the inside of the

pipe with grease MIL-G-24 139. (Grease quantity
1/8 - 1/4 cubic inch (2 cc to 4 cc).
4 Insert piston (1) into pipe (2).
CAUTION
Do not damage the slotted rings when inserting them.
008401
5 Slide new O-ring (1) onto rear cover (2) and coat
with Vaseline.
6 Slide pipe (3) and piston onto the rear cover.
CAUTION
Slide on the pipe so that the stamped number on the
piston faces towards the rear cover.
008402
2-10
7 Coat new O-ring (1) with Vaseline and place it on

the connection plate.
8 Slide connection plate (2) onto threaded pin (3).
NOTE: Make sure the extension piece of the connection

plate faces the bracket on the rear cover.
008403
9 Screw on M8 lock nuts (1) and washers;

NOTE: Use new lock nuts.
008404
2.8 Assembly of retarder accumulator on

1
1 Assemble the retarder accumulator as described in
2.7.
NOTE: The retarder accumulator connection plates (1)

and (2) are different. Ensure the connection plates are
positioned correctly. Assemble the retarder accumulator
on a flat surface plate.
001574
001574
2-11
Oil cooler Ecomat HP 500 / HP 590

of oil cooler.
3.1 Removal of oil cooler.
1 Unscrew and remove hex bolts (1) from the

connection.
1
001575
001575
2 Using a plastic mallet, knock the connection down

off the oil pipes.
3 Remove gaskets (2) from the connection and/or

transmission.
4
2
4 Remove inserts (3) and O-rings (4) from housing
bores.
NOTE: Step 4 only applies for the version with new

housing (from transmission no. 96173; modification 1
no.: 65556).
3
005576
5 Pull oil pipes (1) and O-rings (2) out of the bores in
the oil cooler.
2
001577
001577
2-12
Ecomat HP 500 / HP 590 Oil cooler
6 Unscrew M18x1.5 screw plug (1) and drain the

water from the oil cooler.
008405
7 Remove sealant from oil drain plugs (1) with a

triangular scraper.
8 Unscrew and remove M12x1.5 oil drain plugs (2)

from the oil cooler and drain the oil.
NOTE: Oil drain plugs may or may not be fitted,

depending on the version.
008406
9 Unscrew M10 hex nuts (1) from the bottom of the

oil cooler.
Remove the washers.
008407
2-13
10 Unscrew M10 hex nuts (1).

Remove the washers.
11 Remove (lift) oil cooler (2).
NOTE: If necessary, separate the oil cooler from the

connection pipes by tapping it lightly with a plastic
mallet.
! DANGER
The oil cooler weighs approx. 50 lbs (25 kg).
Take extra care when lifting and transporting it.
008408
3.2 Removal of side-mounted oil cooler.
1 Unscrew and remove M8 hex bolts (2) from the

connection. 1
2 Unscrew and remove hex bolts (3) from retaining

brackets (4) and (5).
3 Remove (lift) the oil cooler and gasket (6).
CAUTION
Remove and transport the oil cooler carefully.
2
001562
4
3
6 5
001561
001562/001561
2-14
3.3 Installation of oil cooler.
1 Coat O-rings (4) with vaseline and place in bores

on housing.
4
2 Place bushes (3) in bores. 2
NOTE: Steps 1 and 1 only apply for the version with

new housing (from transmission no.: 96173;
modification no.: 65556).
1
3 Place connecting piece (1) with gasket (2) on
transmission. Screw in hex bolts; 3
005576
4 Coat O-rings (1) with vaseline and push onto both

ends of the oil pipes. Place oil pipes (2) in
connecting piece.
008410
5 Place oil cooler (1) onto the mounting threads and

push connection pipes into the oil cooler.
6 Screw on hex nuts (2) and washers until hand-tight.
008409
2-15
7 Screw on M10 hex nuts (1) and washers;

008411
8 Thoroughly clean M12x1.5 oil drain plugs (1) and

seats (2).
! DANGER
See special safety regulations for cleaning
agents.
9 Tighten oil drain plugs;

10 Fit the water drain plug with a new M18x1.5

sealing ring (3) and screw it in;
11 Seal oil drain plugs with silicon paste (if oil drain
008412
plugs fitted).
NOTE: Oil drain plugs may or may not be fitted,

depending on version.
2-16
3.4 Installation of side-mounted oil cooler.
1 Attach the retaining bracket to the transmission.
2 Attach the oil cooler to the fixing plate.
3 Coat gaskets (1, 2) with Vaseline and position them 1

on the transmission and oil cooler.
2
4 Screw the pre-assembled connection with inserted
oil pipes onto the oil cooler;
3
5 Screw hex bolts (3) and washers into the
connection;
001561

001561
6 Tighten M10 hex bolts on the retaining bracket;
2-17
3.5 Disassembly of oil cooler.
1 Unscrew seven M8 cap screws (1).
008413
2 Unscrew M8 (1) and M6 (2) cap screws from the

rear of the oil cooler.
008415
3 Unscrew M8 cap screws (1).
4 Drive out the clamping pins.
5 Remove cover (3) from the oil cooler
008414
2-18
6 Remove gasket (1) from the oil cooler housing.
7 Remove gaskets (2) from the heat exchanger.
8 Pull heat exchanger (3) out of the oil cooler housing

and remove silicone partition (4).
NOTE: Because of the O-ring, the heat exchanger is

quite firmly located in the oil cooler housing.
008416
4 Disassembly and assembly of connection

components for side-mounted oil cooler.
4.1 Disassembly of connection components for
1
1 Unscrew hex bolts (1) from pipes (2) and (3) and
2
remove the pipes and gaskets (4) from the oil
cooler. 5
4
2 Pull oil pipes (2) and (3) out of the connection and
slide O-rings (5) off the oil pipes.
5
3
1 001563
001563
4.2 Assembly of oil cooler.
1 Check the heat exchanger for damage and renew it

if necessary.
2 If re-using the same heat exchanger, renew O-ring

(1).
008417
2-19
3 Insert both heat exchangers (1) one after the other

into the oil cooler housing.
4 Insert silicone partition (2) between the two heat

exchangers.
008420
NOTE Clean the metal sealing faces before installing

the gaskets. Use an oil stone, for example.
5 Position new gaskets (1) on the heat exchanger.
6 Position new gasket (2) on the sealing face of the

oil cooler housing.
008419
7 Position cover (1).
8 Drive in clamping pins (2) to center the cover.
NOTE: Do not displace the gaskets when positioning

the cover.
008418
2-20
9 Screw in M8x70 (1) and M8x50 (2) cap screws and

washers until hand-tight.
10 Fit spring washers to the cap screws.
11 Screw in M8x25 (3), M8x50 (2) and M8x70 (1) cap

screws;
12 Screw in M8x20 cap screw (4);

008422
13 Turn the oil cooler over.
14 Fit M8x25 (1) cap screws with spring washers and

screw them in;
008421
2-21
4.3 Assembly of connection components for

1 Coat O-rings (1) with Vaseline and insert them into 2

the groove in the connection piece.
1
2 Insert oil pipes (2, 3) into connection piece (4).
3
001564
001564
2-22
Ecomat HP 500 / HP 590 Converter
5 Removal, installation, disassembly and

assembly of converter.
5.1 Removal of torque converter.
1 Unscrew ten hex or Allen head bolts (1). 2
2 Remove four flex plates from the torque converter.

1
001568
001568
3 Rotate the transmission in its assembly stand so that

the torque converter is pointing upwards.
4 Remove assembly cover (1) using a suitable tool.
NOTE: An M30x1.5 screw plug is mounted instead of

the assembly cover on transmissions from no. 96173
(modification no. 65556).
008423
CAUTION
Do not remove cap screws (1) from around the circum-
ference.
NOTE: Measure and note down installation dimension

“F” (see 5.2.2) before removing the torque converter.
5 Attach bracket brace 1X56 137 658 (2) to the

converter and the transmission housing.
008424
2-23
Converter Ecomat HP 500 / HP 590
6 Unscrew and remove screw plugs (1).
008425
7 Screw holding fixture 1X56 137 158 (1) into the

converter circuit cover until hand-tight.
NOTE: Ensure a rubber washer is fitted on the holding

fixture thread.
008426
NOTE: In addition to the pneumatic holding fixture, it

is also possible to use a ZF mechanical holding fixture
1X56 136 864 together with the hex insert
1X56 136 863.
8 Connect compressed air unit 1X56 137 130 to

holding fixture 1X56 137 158.
9 Open regulator (1) by turning it anti-clockwise.
10 Open cut-off cock (2). Move the lever to horizontal

position.
11 Use the regulator to set a pressure of 22 psi

(1.5 bar).
008427
2-24
12 Insert 1/2” socket wrench extension (1) and loosen

the cap screws.
NOTE: Use suitably long grip. M16 socket head bolt is

tightened to 140 ft-lbs (190 Nm) in the turbine shaft.
13 Close the cut-off cock.
14 Unscrew and remove holding fixture 1X56 137 158

from the converter circuit cover.
008428
15 Unscrew cap screw (1) and remove it from the

converter.
008430
16 Screw lifting device 1X56 136 862 into the

converter and tighten it until hand-tight.
17 Remove bracket brace 1X56 137 658.
18 Carefully remove the converter from the housing.
NOTE: Before lifting out the converter completely,

raise it to just above the turbine shaft. Tip the converter
slightly until the oil has drained from the converter.
008429
2-25
19 Unscrew the lifting device.
20 Turn the converter over and remove shim(s) (1)

either from the converter or from the turbine shaft.
! DANGER
The converter weighs approx. 130 lb. (60 kg).
Secure the converter before removing the lifting
device to prevent it rolling away.
008432
21 Remove spacer ring (1) from the stator quill shaft.
008431
2-26
5.2 Installation of converter.

5.2.1 Measurement of converter end play.
1 Screw lifting device 1X56 136 862 far enough into

the converter until the converter turbine wheel is
clamped tight.
2 Turn the converter over.
! DANGER
The converter weighs approx. 130 lb. (60 kg).
Secure the converter before removing the lifting
device to prevent it rolling away.
008433
3 Measure dimension “C” from the edge of the spur

gear to the turbine wheel contact surface.
4 Note down dimension “C”.
008435
5 Measure dimension “B” from the edge of the spur

gear to the contact surface of the internal sprag
race.
6 Note down dimension “B”.
008434
2-27
7 Calculate theoretical dimension “D” from the

contact face of the internal sprag race to the flat
surface of the turbine wheel as follows.
C-B=D
Note down dimension “D”.
D B
C
001580
001580
8 Check rectangular ring (1) for damage. Renew it if

necessary.
9 Align the rectangular ring centrally.
NOTE: The rectangular ring has hooked ends.
10 Slide spacer ring (2) onto the stator quill shaft and
position it so there is no end play.
008436
11 Screw lifting fixture 1X56 137 213 into the turbine

shaft.
12 Raise the lifting fixture by hand until there is no

end play on the turbine shaft.
13 Place a depth gauge in the recess of the lifting

fixture against the end of the shaft.
14 Measure distance “A” from the end of the turbine

shaft to spacer ring (1) that was slid onto the stator
quill shaft.
15 Note down dimension “A”.
16 Unscrew the lifting fixture from the turbine shaft.

008437
2-28
17 Calculate thickness “S” of shim (1).

D-A=E
Dimension “E” plus the specified converter end play
Dimension “G”* 0.012 to 0.016 inch (0.3 to 0.4 mm),
gives thickness “S” of shim (1) to be installed.
E + 0.012 to 0.016 inch (0.3 to 0.4 mm) = S
Calculation example:
C = 6.99” (174.7 mm) D = 4.78” (119.5 mm)

-B = 2.21” ( 55.2 mm) - A = 4.73” (118.3 mm)
D = 4.78” (119.5 mm) E = 0.05” ( 1.2 mm)
* + G = 0.014” ( 0.35 mm)
S = 0.064” ( 1.55 mm)
CAUTION
Dimension “G” must be added and not subtracted.
Otherwise bearings will be damaged!
Shims are available in the following thicknesses:
0730 362 123 = 1.0 mm (0.041”)

0730 362 218 = 1.1 mm (0.043”)
0730 362 122 = 1.2 mm (0.047”)
0730 362 121 = 1.5 mm (0.059”)
0730 362 219 = 1.7 mm (0.067”)
0730 362 071 = 1.8 mm (0.071”)
0730 362 220 = 1.9 mm (0.074”)
0730 362 070 = 2.0 mm (0.078”)
0730 362 120 = 2.5 mm (0.098”)
0730 362 067 = 2.6 mm (0.102”)
NOTE: Thicker shims mean larger play.
18 Thinly coat shim (1) with grease and attach.
19 Center the shim.
20 Center the rectangular ring.
21 Thinly coat the running surface of sealing ring (2)

with oil.
008438
2-29
22 Screw lifting device 1X56 136 862 into the

converter.
23 Carefully lower the converter onto the transmission

with its turbine shaft centered. Position the
converter so there is no end play.
008439
24 Loosen lifting device 1X56 136 862 by unscrewing

it a few turns.
CAUTION
Do not damage the sealing ring. Ensure the shim is
correctly positioned on the turbine shaft.
NOTE: The turbine shaft splines must mesh with the

stator quill shaft splines. If necessary, turn the converter
slightly to engage it. The gear on the converter must
also mesh with the input gear of the primary pump.
008440
2-30
5.2.2 Measurement of installation dimension of

converter.
1 Ensure the torque converter has been inserted

correctly and there is no end play.
2 Measure installation dimension “F” from the
converter mounting face to the transmission
mounting face.
3 Measure dimension “F” at several points around the
circumference to obtain the average value.
NOTE: Installation dimension “F” must be X ± 0.02”

(0.5 mm). Ecomat transmissions are equipped with
different converter versions. The table below gives the
installation dimensions for dimension “F” (converter)
according to the converter type.
008441
External ø External ø
~ 17” (430 mm) ~ 19” (475 mm)
X = 2 25/32” (71.25 mm)

X = 3” (77.00 mm) X = 3” (77.00 mm)
X = 3 11/64” (81.25 mm) X = 3 11/64” (81.25 mm)
Außen Ø
X = 3 23/64” (86.25 mm)
If installation dimension “F” lies between X + 0.02”

(0.5 mm) and X - 0.02” (0.5 mm), the setting is correct.
4 If the installation dimension is smaller than

X - 0.02” (0.5 mm), fit a second shim on the stator
F
quill shaft.
5 If the installation dimension is greater that

X + 0.02” (0.5 mm), remove the shim.
001581
NOTE: The spacer ring is 0.04” (1 mm) thick.
CAUTION
If dimension “F” is reset by changing the shim on the
stator quill shaft, the shim on the turbine shaft must also
be changed accordingly. Otherwise bearing failure will
result.
6 Unscrew and remove the lifting device

1X56 136 862 from the converter.
7 Screw M16 cap screw (1) into the converter.
8 Check the installation dimension again.
008442
2-31
9 Insert brace bracket 1X56 137 658 into the

transmission housing and screw it onto the
converter.
10 Screw holding fixture 1X56 137 158 into the

converter circuit cover until hand-tight.
NOTE: Ensure rubber washeris fitted on the holding

fixture thread.
008443
11 Connect compressed air unit 1X56 137 130 to

holding fixture 1X56 137 158.
12 Turn regulator (1) anti-clockwise to open it.
13 Open the cut-off cock. Move lever (2) to the

horizontal position.
14 Use the regulator to set a pressure of 22 psi

(1.5 bar).
15 Insert 1/2" socket wrench extension (3) and tighten

the cap screws;
Tightening torque: 133 - 140 ft-lbs (180 - 190 Nm).
16 Close the cut-off cock.
17 Unscrew and remove holding fixture 1X56 137 158

from the converter circuit cover.
2-32
18 Fit new copper sealing washer (1) to screw plug (2).
19 Tighten the M33x2 screw plug;

Tightening torque: 140 - 150 ft-lbs (190 - 210 Nm).
008444
20 Insert cover (1) into the assembly aperture.
NOTE: A screw plug is installed instead of the circuit

cover in transmissions from no. 96173 (modification no.
65556).
Tighten M30x1.5 screw plug to 44 ft-lbs (60 Nm).
008445
NOTE: Follow the manufacturer’s instructions if flex

plates are fitted to the engine.
21 Tighten ten M12x1.5 hex or Allen head bolts (1);

001568
001568
2-33
5.3 Disassembly of converter.
1 Turn the torque converter over and place it on

planks.
2 Unscrew and remove all M8 and M10 cap screws

(1).
3 Press off the circuit cover from the impeller by

screwing in lifting device 1X56 136 862.
CAUTION
Do not use a hammer on the circuit cover or the
impeller.
008446
4 Remove the roller bearing and shaft disc from the

stator.
008448
5 Unscrew and remove twelve M8 cap screws (1).
6 Slightly raise impeller (2) and, using a plastic

mallet, drive out spur gear (3).
NOTE: On transmissions with PTOs, the spur gear and

impeller are fitted with four clamping pins. If necessary,
drive out the clamping pins.
008447
2-34
7 Remove housing disc (1) from spur gear (2).
8 Remove O-ring (3) and gasket (4) from the spur

gear.
CAUTION
Do not swap shaft and housing discs between any other
bearing packs. Mark them accordingly.
008449
9 Remove the complete stator from the turbine wheel.
10 Remove shaft disc (1) from the stator.
11 Remove needle bearing (2) from the turbine wheel.
008450
12 Remove housing disc (1) and shim (2) from the

turbine shaft.
CAUTION
Do not switch over bearing packs during installation.
008451
2-35
Stator Ecomat HP 500 / HP 590
5.3.1 Disassembly of stator.
1 Place stator (1) on a support.
2 Place appropriate pressure piece (2) on freewheel

ring (3).
3 Press out freewheel ring from stator.
008452
4 Remove rollers (1) from the freewheel ring.
5 Remove axial disc (2) from the freewheel ring.
008453
6 Press out freewheel ring (1) ball bearing (2).
! DANGER
Do not clean bearing with compressed air. The
bearing races could come loose and damage the
bearing due to lack of lubrication.
008454
2-36
Ecomat HP 500 / HP 590 Stator
7 Place stator (1) on press using appropriate support

(2).
8 Use suitable pressure piece(s) to press out ball

bearing from stator.
CAUTION
The diameter of the pressure piece must match the
external diameter of the bearing.
008455
9 Remove ball bearing (1) and axial shim (2) from the
stator.
008457
5.3.2 Assembly of stator.
1 Insert the axial shim into the stator.
2 Place the stator and ball bearing in the press using

an appropriate support.
3 Use special tool 1X56 137 152 to press in the

bearing fully.
008456
2-37
Stator Ecomat HP 500 / HP 590
4 Insert support 1X56 137 152 into press with recess

facing upwards.
5 Turn the stator over and place it on support

1X56 137 152.
6 Insert freewheel ring (1) into the stator with its

longer collar facing downwards. Press in the
freewheel ring.
NOTE: The installation dimension of the freewheel ring

is given by the support 1X56 137 152.
008459
7 Insert the rollers into the stator.
NOTE: After insertion, oil the rollers well and rotate

the stator a few times.
8 Insert axial disc (1) into the stator.
008460
9 Insert support 1X56 137 152 in press and place the

stator complete with the ball bearing onto the
support.
10 Place second support 1X56 137 152 onto the ball

bearing.
11 Press the ball bearing fully into the stator.
NOTE: Ensure the recesses on both supports

1X56 137 152 face the stator. The installation
dimension is given by the supports.
008458
2-38
Ecomat HP 500 / HP 590 Turbine wheel / Circuit cover
5.3.3 Disassembly of turbine wheel and circuit cover.
1 Remove turbine wheel (1) from circuit cover (2)

using suitable assembly irons.
008462
2 Remove rectangular ring (1) from the annular

groove.
NOTE: The rectangular ring has sharp edges.

Press the end of the rectangular ring down into the
groove base using your thumb. Slide your index finger
to the other end of the rectangular ring until the ring
disengages.
008463
3 Press off ball bearing (1) from turbine wheel (2)

using two assembly levers.
NOTE: Do not remove disc (3) if it is undamaged.
008461
2-39
Turbine wheel / Circuit cover Ecomat HP 500 / HP 590
4 Drive out disc (3) (see Step 3) from the turbine

wheel, from the rear using a suitable punch.
008464
5 Unscrew twelve hex bolts (1) from end disc (2) and
remove the end disc.
008466
NOTE: Steps 6 to 8 only apply for HP 500 converter

version (external diameter 17” / 430 mm).
6 Remove the inner and outer discs from the circuit

cover.
7 Remove cup spring (1).
8 Remove the rollers.
008465
2-40

version (outer diameter 19” / 475 mm).
9 Remove inner and outer discs (1/2) from circuit 1

cover.
NOTE: The pressure springs are located on the last

outer disc (2). Remove pressure springs with last outer
disc.
10 Remove cup springs (4).
11 Remove rollers (5).

2 5
4
3
003971
12 Grip plate piston (1) using a pair of pliers.
13 Lightly tap sealing surface (2) of the circuit cover

with a plastic hammer. This loosens the plate piston
and allows it to be removed.
008467
14 Hook an appropriate tool (1/64” - 1/32” / 0.5 -

0.75 mm thick) under inner rectangular ring (2) and
carefully remove it from the plate piston. 1
! DANGER
Grooved edge of plate piston may have sharp edges.
Wear protective gloves at all times
2
15 Push outer rectangular ring (1) on both sides as
shown by arrows. Grasp protruding section of
rectangular ring and remove from groove.
The basic procedure for removing all external

rectangular rings is the same.
001569
001569
2-41
5.3.4 Assembly of circuit cover and turbine wheel.
NOTE: Clean all components thoroughly and dry them

using compressed air. Only use lint-free cloths to wipe
down the rectangular rings.
1 Check the rectangular rings for damage and renew

them if necessary.
2 Coat inner rectangular ring (2) and outer

rectangular ring (1) with Vaseline and insert them
into the plate piston.
NOTE: Stretch the inner rectangular ring slightly before

installing it so it locates firmly against the groove base.
008468
CAUTION
Insert plate piston (1) into circuit cover. Ensure the plate
piston is not misaligned. Ensure the rectangular rings
are firmly located against the ring groove base around
their entire circumference.
3 Tap the circumference of the plate piston lightly

with a plastic mallet. Ensure the plate piston lies
flat.
4 Insert twelve rollers (2) into the bores around the

circumference.
5 Place the cup spring on the plate piston with its

camber facing downwards.
008470
6 Using a straight-edge, check that the outer and inner

discs are level and not distorted. Perform a visual
check. Check the discs against the end disc or a flat
surface.
CAUTION
Dished or corrugated discs must be replaced. Maximum
permissible wear 0.012” (0.3 mm).
Coated discs with damaged or blackened coating must be
replaced. Inner discs with damaged tooth flanks must be
replaced.
Permissible wear per tooth flank: 0.008” (0.2 mm).
008469
2-42

7 Insert outer disc (1).
8 Insert inner disc (2).
9 Depending on the version, insert one or two outer

discs (3).
10 Insert inner disc (4) into the circuit cover.
NOTE: Insert outer discs (3) so that the bores slide over
the rollers.
008471

11 Position outer disc (1) so that bores slide over 5

rollers.
12 Position four springs (2) over the rollers on the

outer disc at 90° intervals. Check position of
springs in relation to recess on circuit cover.
14 Insert two outer discs (4) over remaining rollers

4
ensuring tooth spaces are aligned with springs and 3
bores.
1
2
003971
16 Insert end disc (1) into the circuit cover.
17 Line up the bores in the end disc with the bores in

the circuit cover.
18 Tighten M8 hex bolts;

NOTE: Before tightening the hex bolts, tap the plate

piston once again with a plastic mallet to ensure it is
lying flat.
008472
2-43
19 Using feeler gauge (1), measure the disc play

between the last inner disc and end disc (2), and
note down as dimension “A”.
20 Permissible play: 0.02” to 0.044” (0.5 to 1.1 mm).
008473
A
NOTE: If disc play is less than 0.02” (0.5 mm) or more
than 0.044” (1.1 mm), install suitable new outer discs.
Then, remeasure dimension “A”.
A
Outer discs can be supplied in the following thicknesses:
converter
004 234
HP590 converter outer dia. 19” (475 mm) outer dia. 19” (475 mm)
4139 338 002 = 0.118” (3.0 mm)
4139 338 206 = 0.138” (3.5 mm) A
HP500 converter outer dia. 17” (430 mm)

4139 334 005 = 0.138” (3.5 mm)
A
4139 334 006 = 0.157” (4.0 mm)
converter
001 570
outer dia. 17” (430 mm)
004234/001570
21 Turn over the turbine wheel. If spacer disc (1) was

removed, drive in spacer disc (1) fully.
22 Using a center punch, secure the spacer disc four

times around its circumference.
NOTE: Install the spacer disc with bores (2) facing

upwards.
008474
2-44
23 Using a suitable tube, drive the ball bearing onto

the turbine wheel.
24 Insert rectangular ring (1) into annular groove (2)

and hook in the open ends of the rectangular ring.
! DANGER
The rectangular ring has sharp edges. Use
protective gloves.
008475
25 Line up the inner discs. The discs should cover each

other.
26 Insert turbine wheel (1) into the circuit cover.
CAUTION
Ensure the gearing on the turbine wheel meshes with the
teeth on the inner discs. Rotate the turbine wheel
backwards and forwards until it engages. Ensure the
turbine wheel is fully engaged and positioned evenly. If
necessary, lightly tap the edge of the inner gearing using
a plastic mallet.
Take care not to damage the inner discs.
008476
2-45
Torque converter Ecomat HP 500 / HP 590
5.4 Assembly of torque converter.
CAUTION
Rework necessary during repairs:
New O-ring seal on HP 590 torque converter (outer dia.
19” / 475 mm) with 36 bolts around circumference.
Machine O-ring groove in pump wheel.
See Section 5.4.1.1 - extra page 52/1.
1 Clean the spur gear and use an oil stone to clean the
sealing surface.
2 Place the bearing packet near to hand. Note its

markings!
3 Insert housing disc (2) in the spur gear.

008477
CAUTION
Ensure its chamfered side is facing the spur gear.
NOTE: Plate (1) is marked “WS” and housing disc (2)

is marked “GS”.
008478
4 Position new O-ring (1) in spur gear (2).
5 Position new gasket (3) on sealing face of spur gear

(2) and align with bores.
008479
2-46
Ecomat HP 500 / HP 590 Torque converter
6 Align spur gear with bores in pump wheel.
7 Place spur gear in pump wheel.
NOTE: The spur gear and pump wheel are fixed with 4
slotted pins in transmissions with PTOs. If required,
drive in slotted pins.
8 Turn over pump wheel complete with spur gear.
9 Insert 12 new Torx-Powerlok screws and tighten to

26 ft-lbs (35 Nm).
008480
CAUTION
Always use new Powerlok screws. The countersunk
screwhead bores in the pump wheel must be flat. If
required, sink once by max. 0.02” (0.5 mm).
10 Place roller bearing (1) onto the housing disc in the

impeller.
11 Place plate (2) onto the roller bearing with its

chamfer facing upwards.
12 Place 0.02” (0.5 mm) thick shim (3) onto the plate.
008481
13 Insert complete stator (1) into the impeller.
CAUTION
Ensure longer collar (2) of the freewheel ring faces the
impeller. When inserting the stator, ensure that the
freewheel ring and bearings do not fall out of the stator.
NOTE: Place support 1X56 137 152 onto the stator

bearing. Using a plastic mallet, drive in the stator and
complete bearing pack with light taps until fully
inserted.
008482
2-47
14 Place the marked bearing pack near to hand.
15 Place shaft disc (1) onto the stator.
16 Place needle cage (2) onto the shaft disc.
17 Place housing disc (3) onto the needle cage.
008483
5.4.1 Measurement and setting of end play of axial

bearings.
1 Place new gasket (3) on sealing face.
NOTE: If there is an O-ring seal on the HP 590 torque

converter (outer diameter 19” / 475 mm with 36 bolts
around circumference), measure without the gasket.
2 Place measurement blocks (1) onto the sealing

surface of the impeller.
3 Place measurement bar (2) onto the measurement

blocks.
4 Place a depth gauge onto the measurement bar and

measure dimension “A” from the measurement bar 008485
to the impeller sealing surface with its gasket in
place. Note down dimension “A”.
NOTE: Make sure the measurement bar does not touch

the stator.
5 Slide the depth gauge along the bar to the

center.
6 Measure dimension “B” from the measurement bar

to the face of housing disc (1).
7 Note down dimension “B” and subtract it from

dimension “A”.
Dimension “A” - Dimension “B” = Dimension “C”

008484
2-48
8 Place the measurement apparatus on the circuit

cover.
NOTE: Do not place a gasket on the circuit cover for

this measurement.
9 Using a depth gauge, measure dimension “D” from

the measurement bar to the circuit cover sealing
surface.
10 Note down dimension “D”.
008486
11 Measure dimension “E” from the measurement bar

to the contact surface for spacer (1).
12 Note down dimension “E” and subtract from it

dimension “D”.
Dimension “D” - Dimension “E” = Dimension “F”

Subtract dimension “F” from dimension “C”
Dimension “C” - Dimension “F” = Dimension “G”
13 Calculate the thickness “S” of the spacer disc to be

inserted as follows:
G - (0.004 to 0.01” / 0.1 - 0.3 mm) = S
0.004 to 0.01” (0.1 - 0.3 mm) = end play of axial

bearing
008487
Sample calculation:
G = 0.055” (1.4 mm)

-*H = 0.008” (0.2 mm) Spacer discs can be obtained in multiples of
S = 0.047” (1.2 mm) 0.008” (0.2 mm) thickness:
*H = average of 0.004 and 0.012” 0630 000 219 = 1.0 mm (0.041”)

(0.1 mm and 0.3 mm) end play 0630 004 152 = 1.2 mm (0.047”)
0630 004 154 = 1.4 mm (0.055”)
0630 004 156 = 1.6 mm (0.063”)
CAUTION 0630 004 158 = 1.8 mm (0.071”)
The figures in this calculation are purely theoretical. 0630 004 127 = 2.0 mm (0.078”)
0730 000 982 = 2.2 mm (0.086”)
2-49
14 Insert spacer disc (1) into the turbine wheel.
008488
15 Remove the upper housing disc from the stator.
16 Insert housing disc (1) into the turbine wheel with

its chamfered edge facing towards spacer disc (2).
17 Remove the needle sleeve from the stator and insert

it into the turbine wheel.
008489
18 Remove complete stator (1) from the impeller.

Insert stator (1) into the turbine wheel with the
short collar of the freewheel ring facing the turbine
wheel.
NOTE: Coat all bearings with oil before installation.
19 Remove plate (2) from the impeller. Place plate (2)

onto the stator with its chamfered edge facing the
stator.
008490
2-50
20 Remove roller bearing (1) from the impeller. Place

roller bearing (1) onto the stator.
008491

version (external diameter 17” / 430 mm).
21 Lay gasket (1) onto the circuit cover.
22 Screw two M8 guide bolts 1X56 136 821 (2) into

opposite sides of the circuit cover flange.
008492
23 Place impeller (1) onto the circuit cover.
24 Unscrew M8 guide bolts 1X156 136 821 (2) and

remove them.
008493
2-51
25 Fit 36 M8 cap screws (1) with one washer each.
26 Tighten cap screws:

Tightening torque = 25 ft-lbs (34 Nm).
008494
27 Check the end play of the freewheel ring (1).
28 Hold the inside of the freewheel ring with both your

hands and try to move it axially. You must be able
to feel the end play.
008495
2-52
5.4.1.1 New O-ring seal on HP 590 converter

(ZFW 380-30) fitted during repairs DETAIL X 3
1
NOTE:
This repair solution applies for all ZFW 380-30 torque
converters with an external diameter of 19” (475 mm)
and 36 bolts for affixing pump wheel with circuit cover.
1 Pump wheel depending on spec. list

2 O-ring 420x2.5
3 Cylindrical screw M10x55
2
Parts required:
005272
Qty. Item no. Description Made from
1 * 4166 338 221 Pump wheel 4166 338 136

* 4166 338 222 4166 338 137
* 4166 338 223 4166 338 194
* 4166 338 224 4166 338 205
1 0634 314 402 O-ring

36 0636 101 900 Cylindrical screw
* Depending on spec. list
NOTE: The gasket used previously has been omitted.
Procuring remachined pump wheels:
a) Purchase from ZF Friedrichshafen AG:

- Item no. of pump wheel depending on spec. list
b) Remachining:
- by After-Sales Service Centre
- or a mechanical workshop appointed by
ZF Friedrichshafen AG
- or enduser
providing suitable equipment is available.
CAUTION
Remachining must be carried out in accordance with
drawing 4166 338 220 and is only permitted on pump
wheels in perfect condition.
005552
2-52-1
Checking used pump wheels:
Calculate the distance between the spur gear/pump

wheel sealing face and pump wheel/circuit cover sealing
face.
Permissible distance = max. 3.9488” (100.3 mm).
CAUTION
If this distance is greater, the pump wheel has widened
and must not be re-used.
Permissible distance
on used pump wheels
max. 3.9488”
(100.3 mm)
005560
CAUTION
On used pump wheels, which previously had M10x50
screws, the M10 thread must be remachined along the
whole thread.
005552
2-52-2
Machining O-ring groove in pump wheel:

11 22
005559
CAUTION
min.
20 0.8” (20 mm)
min.
Remachining must be carried out in accordance with
M8
drawing 4166 338 220 and is only permissible on pump
wheels in perfect condition.
5.0393 ± 0.008” 4x90 deg.

- 0.00138”
(ø104,985 - 0,035 mm)
(4x90°)
mm)
5.9” (ø150 mm)
6.3” (ø160 mm)

ø104,985-0,035
If possible, a clamping flange (1) should be used to hold
128 ± 0,2
LKR. 128±0,2
the pump wheel in the 3-jaw chuck (above spur gear
Dia. 4.13327
Dia. ø160
Dia.ø150
centring bore).
(LKR.
To avoid vibrations (rattling) when machining, the
spindle face must be pushed against the pump wheel
blades using a suitable plate (2).
0.2 ” 0.8”
20 (20 mm)
(5 mm)
5
1”
25 (25 mm)
Clamping flange
005551
The face (previous sealing face) of the pump wheel must

be flat and free of raised material.
If necessary, the face may be re-machined by a maximum
0.118+0.008”
of 0.008” (0.2 mm) to ensure it is perfectly flat.

(3 +0,2 mm)
NOTE: The depth 0.0748 +0.004” (1.9+0.1 mm) for the

O-ring groove refers to the finished machined face.
0.0748 +0.004”
(1.9+0.1 mm)
Dia. A
Ref. no. Made from Dia. A

4166 338 221 4166 338 136 16.929” (430 mm)
4166 338 222 4166 338 137 16.929” (430 mm) Face without
raised material
4166 338 223 4166 338 194 17.047” (433 mm)
4166 338 224 4166 338 205 17.047” (433 mm)
00
005560
2-52-3
Reassembling HP 590 converter

(outer diameter 19” / 475) - continued -
CAUTION
Following omission of the gasket, the end play setting
on the axial roller bearing has changed.
Remeasure and reset end play of axial roller bearing as
described under Section 5.4.1.
003393
1 Pump wheel
2 End shim/disc
1
3 O-ring 420x2.5
4 Circuit cover
5 Cylindrical screw M10x55
29 Place circuit cover (4) on wooden blocks.

2
30 Place O-ring (3) over end shim (2) on circuit cover
sealing face (4). 3
31 Insert two opposite facing M10 threaded pins in

pump wheel (1) flange.
5
4
32 Place pump wheel (1) on circuit cover (4).
005272
33 Unscrew threaded pins.
34 Insert four M10x25 cylindrical screws (5) and

tighten by hand.
CAUTION
The cylindrical screws (5) are coated.
Always use new cylindrical screws.
5
35 Turn converter and place on two wooden blocks.
Insert remaining M10x55 cylindrical screws (5) and
tighten to 44 ft-lbs (60 Nm).
Check end play of freewheel inner ring as described on

page 52, Step 28.
004289
2-52-4
5.4.2 Check for converter leaks.
1 Insert forcing device 1X56 137 129 into the spur

gear side of the converter.
008496
2 Screw a locking nut onto the forcing device.
! DANGER
Torque converter weighs approx. 130 lbs.
(60 kg).
008497
3 Use lifting device to submerge the converter in a

water tank until the sealing face (1) between the
impeller and the spur gear is just beneath the water
surface. 1
4 Connect compressed air unit 1X56 137 130 to the

forcing device.
CAUTION
Mix water in tank with anti-freeze (1:120 solution).
Water temperature = 68 °F (20°C).
003 127
003127
2-53
5 Turn regulator (1) counter-clockwise.
6 Open the shut-off cock.

1 2
7 Set the pressure to 36.5 psi (2.5 bar) using
regulator (1).
CAUTION
There must not be any converter leaks whatsoever.
003126
8 Shut off compressed air unit 1X56 137 130 and

disconnect from forcing device 1X56 137 129.
9 Use a lifting device to lift the converter out of the

tank. Lower the converter onto a worktop.
10 Remove the lifting device and turn the converter

over.
11 Unscrew locking nut (1) and remove it.
008499
12 Fit the converter onto the circuit cover and remove

forcing device 1X56 137 129 from the converter.
NOTE: Dry the converter using compressed air. Apply

a thin coat of oil to the spur gear.
008498
2-54
Ecomat HP 500 / HP 590 Cover plate
6 Removal and installation of cover plate.

6.1 Removal of cover plate.
-Remove the converter (see Section 5.1)
NOTE: Tilt the transmission to drain oil before

removing the cover plate.
1 Remove union screws (2).
2 Remove the union screws, sealing washers and oil

pipe (1) from the cover plate.
008500
3 Unscrew nineteen M8 hex bolts (1) and remove

them from cover the plate together with their
sealing washers.
4 Unscrew and remove fifteen M8 cap screws (2).
008501
5 Screw the threaded spindles (1) of three extractors

1X56 136 815 into the threaded bores provided.
008502
2-55
Cover plate Ecomat HP 500 / HP 590
6 Place bars (1) of extractors 1X56 136 815 onto

threaded spindles and screw on clamping nuts (2).
7 Tighten the clamping nuts evenly, alternating from

bar to bar. Pull out the cover plate.
8 Unscrew extractors 1X56 136 815 from the cover

plate and remove them.
008503
2-56
Ecomat HP 500 / HP 590 Cover plate
6.2 Installation of cover plate.
1 Check shaft seal (1) for damage.
2 If necessary, press out the shaft seal from cover

plate from the rear.
3 Fit new O-ring (2) onto the cover plate.
4 Apply a thin coat of Vaseline to the O-ring and the

sealing face of the cover plate.
008504
5 Screw a stud bolt into the control insert for fixing

purposes. Insert the cover plate, ensuring it is lined
up correctly.
6 Drive in the cover plate by tapping it evenly around

its edge with a plastic mallet. Ensure the cover plate
is fully inserted.
CAUTION
A new copper seal, washer, new copper seal (in this
order) must be placed under the socket head screws on
each of the three screw bores with a thread (arrow). This
is a special seal combination.
7 Fit M8x130 cap screws (1) with new copper

washers and screw them in;
008505
Tightening torque: 17ft-lbs (23 Nm).
8 Fit M8x40 cap screw (2) with new copper

9 Fit eight M8x85 hex bolts (3) with new copper

10 Fit eleven M8x20 hex bolts (4) with new copper

2-57
Cover plate Ecomat HP 500 / HP 590
11 Insert oil pipe (1).
12 Tighten union screws (2);

CAUTION
Fit two copper sealing washers on each union screw
connection: one under the screw head and one under the
oil pipe connection.
008506
13 Insert the shaft seal as follows.
14 Lightly coat the outside of the shaft seal with a

lubricant.
NOTE: Use water soluble washing-up liquid as

lubricant.
15 Coat the sealing lip(s) with Vaseline.
16 Position the shaft seal against the hole with its

sealing lip(s) facing the cover plate.
17 Drive in the shaft seal using punch

1X56 136 605. Make sure the seal is fully inserted.
008507
2-58
Ecomat HP 500 / HP 590 Oil pan
7 Removal and installation of oil pan

7.1 Removal of oil pan
1 Unscrew four M8 hex bolts (1) and remove together

with washers.
2 Remove cover (2) from the filter housing.
008508
3 Pull off the screen filter (1) from intake tube.
008509
4 Unscrew and remove thirty-three M8 hex bolts (1)

together with washers from around the edge of the
oil pan.
5 Remove oil pan (2) and its gasket from the

transmission.
008510
2-59
Oil pan Ecomat HP 500 / HP 590
7.2 Installation of oil sump.
1 Place new gasket (1) onto the sealing face.
008511
2 Lay the oil pan on the transmission.
NOTE: Ensure the gasket is not displaced when

positioning the oil pan.
3 Fit hex bolts (1) with washers. Screw in the hex

bolts and tighten them;
NOTE: Fit hex bolts (2) with new copper sealing

washers.
008512
4 Apply a light coating of Vaseline to O-ring (1) in

the screen filter.
008513
2-60
Ecomat HP 500 / HP 590 Oil pan
5 Push screen filter (1) onto the intake tube until it is

fully inserted.
008516
6 Insert new O-ring (1) into cover (2).
7 Apply a light coat of Vaseline to the O-ring.
008514
8 Place cover (1) onto the oil pan.
9 Fit M8x80 hex bolts (2) with washers. Screw in and

tighten the hex bolts;
008515
2-61
Inductive sensor Ecomat HP 500 / HP 590
8 Removal and installation of inductive sensor.

8.1 Removal of inductive sensor.
1 Unscrew and remove screw plug (1).
008517
2 Remove cable plug (1) from inductive sensor using

a pair of flat-nose pliers.
3 Use a socket wrench and extension piece to

unscrew the inductive sensor (2).
008518
4 Remove inductive sensor (1) and shim(s) (2).
NOTE: A shim may remain stuck on the fixing plate in

the transmission.
008519
2-62
Ecomat HP 500 / HP 590 Inductive sensor
8.2 Installation of inductive sensor.
1 Swing the transmission into the installation

position.
2 Place small a screwdriver against the inductive

sensor ring.
3 Use an assembly lever to rotate the output flange.

Using the small screwdriver, establish where the
projection on the impulse sensor ring is located.
008520
4 Stop turning the output flange when one of the

projections is located under the inductive sensor
insertion bore.
5 Screw sliding ring (1) approx. 1/4” (6 mm) onto

measurement rod 1P01 137 833.
6 Insert measurement rod 1P01 137 833 into the

inductive sensor bore until the end of the
measurement rod touches the projection on the
impulse sensor ring.
NOTE: Measure the highest point on the impulse sensor

ring. Ensure the measurement rod is positioned verti-
cally in the threaded bore.
008521
CAUTION
Ensure a projection on the impulse sensor ring is located
directly underneath the threaded bore for the inductive
sensor. If this measurement is made at a lower point on
the impulse sensor ring, the inductive sensor will collide
with the projections when the engine is started, and will
be damaged.
1 = Impulse sensor ring

2 = Fixing plate
3 = Measurement rod 1P01 137 833
001571
1 2 3
001571
2-63
7 Withdraw measurement rod 1P01 137 833.
8 Measure dimension “B” from the end of the

measurement rod to sliding ring (1).
CAUTION
Ensure sliding ring (1) does not move after the measure-
ment rod is withdrawn from the bore.
008523
10 Measure dimension “C” on the inductive sensor

from its contact surface to the shim contact surface.
11 Subtract dimension “B” from dimension “C”.

C-B=D
12 Note down dimension “D”.
008523
2-64
Ecomat HP 500 / HP 590 Inductive sensor
NOTE: Ensure dimension “A” is between 0.023” and

0.031” (0.6 to 0.8 mm). Set dimension “A” using a shim
(4) of the correct thickness. 1
1 = Impulse sensor ring

2 = Fixing plate 2
3 = Inductive sensor (speed sensor)
4 = Shim
13 Calculate the thickness of the shim as follows: 3
14 D + A = thickness “S” of the shim.
NOTE: The figures in the example below are purely 4

A
theoretical.
001572
Example:
001572
B = 0.936” (24 mm)

C = 1.014” (26 mm)
A = 0.023” to 0.031” (0.6 to 0.8 mm)
D=C-B
D = 1.014” - 0.936” (26 mm - 24 mm)
D = 0.078” (2 mm)
S=D+A
S = 0.078” + 0.023 to 0.031”
(2 mm + 0.6 to 0.8 mm)
S = 0.102 to 0.110” (2.6 to 2.8 mm)
15 Shims (1) are available in the following thicknesses.
0730 003 049 = 0.6 mm (0.023”)

0730 003 050 = 0.8 mm (0.031”)
0730 002 069 = 1.0 mm (0.041”)
0730 002 068 = 1.2 mm (0.047”)
0730 002 067 = 1.4 mm (0.055”)
0730 002 066 = 1.6 mm (0.062”)
0730 002 065 = 1.8 mm (0.071”)
0730 002 064 = 2.0 mm (0.078”)
0730 002 063 = 2.2 mm (0.086”)
0730 002 062 = 2.4 mm (0.094”)
0730 002 061 = 2.6 mm (0.102”)
0730 003 299 = 2.8 mm (0.110”)
0730 003 300 = 3.0 mm (0.118”)
008524
2-65
16 Fit the shim(s) onto inductive sensor (1). Screw in

the inductive sensor and tighten it;
Tightening torque: 37 ft-lbs (50 Nm); do not
exceed.
17 Connect cable plug (2) onto the inductive sensor.

There is no need to observe correct polarity when
fitting this cable plug.
008525
18 Use an inner hex head driver to tighten M42x2

screw plugs (1);
Tightening torque: 60 to 74 ft-lbs (80 to 100 Nm).
008526
2-66
Ecomat HP 500 / HP 590 Hydraulic transmission control unit

of hydraulic transmission control unit.
9.1 Removal of hydraulic transmission control unit.
1 Unscrew M8 hex bolts (1) and remove together with

washers.
2 Push the cannon socket into the transmission

housing.
008527
3 Rotate the transmission in its assembly stand so the

hydraulic control unit is at the top.
4 Disconnect the plug from the socket.
008528
NOTE: The plug connection (1) is held together by a

tooth and notch profile. Use a small screwdriver to
disconnect the plug and socket.
008529
2-67
Hydraulic transmission control unit Ecomat HP 500 / HP 590
6 Unscrew and remove thirty-nine M8 hex bolts (1)

together with washers.
CAUTION
Do not loosen M6 hex bolts.
7 Remove complete hydraulic control unit (2) from

the transmission. Take care not to damage the
connections when doing this.
! DANGER
The hydraulic control unit weighs 40 lbs.
(18 kg). Watch out for sharp edges.
008530
9.1.1 Retrofitting impurity collecting magnets on

hydraulic control unit
4 x magnetic discs
Components:
- 4 x magnetic discs - ref. no. 4139 306 673
Purchased from:
- ZF Friedrichshafen AG
NOTE: The magnetic discs have been installed during

production since transmission no. 078844.
005547
CAUTION
If magnetic discs have not already been fitted, these
must be retrofitted during repairs.
Configuration:
Attach two magnetic discs each to valve blocks A and B
as shown.
005549
2-68
9.2 Installation of hydraulic transmission control

unit.
1 Insert the hydraulic control unit into the

transmission.
NOTE: Make sure the cannon socket slides into its seat
in the transmission housing. Make sure the fixing lug of
the socket points towards the transmission input. Do not
trap the inductive sensor cables.
008532
2 Fit nine M8x35 hex bolts (1) with washers. Screw

them in, but do not tighten them.
008533
3 Fit thirty M8x45 hex bolts (1) with washers. Screw

them in and tighten them;
Now tighten the bolts inserted in Step 2.
NOTE: Work from the center to the edges when

tightening these bolts.
008531
2-69
4 Connect plug and socket (1) for the inductive

sensor. The plug connection is coded for polarity.
008534
5 Line up cannon socket (1) with the bolt holes.
6 Fit M8x28 hex bolts (2) with washers. Screw the in

and tighten them;
- See Section 8.2 for installation of the inductive

sensor.
- See Section 7.2 for installation of the oil pan.
008535
2-70
9.3 Disassembly of hydraulic control unit.
Valve block A:
1 = Solenoid valve for brake “F”
2 = Solenoid valve for lock-up clutch “WK”
3 = Solenoid valve for clutch “C”
4 = Solenoid valve for clutch “A”
Valve block B:
5 = Solenoid valve for clutch “B”
6 = Solenoid valve for brake “E”
7 = Solenoid valve for brake “D”
8 = Solenoid valve for brake “G” / NBS option
008536
1 Pull the flat-pin plugs off the solenoid valves.
2 Unscrew and remove M5 cap screws (2) from the

solenoid valves (1).
3 Pull the solenoid valves out of the valve blocks.
008538
4 Pull flat-pin plug (1) off throttle valve (2).
008537
2-71
5 Turn the hydraulic control unit over.
6 Unscrew and remove M6 hex bolts (1) and remove

the throttle valve from the duct plate.
008539
2-72
Ecomat HP 500 / HP 590 Throttle valve
9.3.1 Disassembly of throttle valve.
1 Unscrew and remove M5 cap screws (1).
2 Remove switching solenoid (2) from the throttle

valve.
008540
3 Unscrew and remove M6 hex bolts.
4 Take cover (2) off the throttle valve.
5 Remove all pistons and balls (1) from the valve

housing.
008541
6 Unscrew and remove M6 hex bolts (1).
008542
2-73
Throttle valve Ecomat HP 500 / HP 590
7 Remove cover (1) and gasket (2).
008543
8 Check filter (1).
008544
2-74
Ecomat HP 500 / HP 590 Throttle valve
9.3.2 Assembly of throttle valve.
1 Check screen (1) and replace if necessary.
008545
2 Insert piston (1) into the valve housing.
008546
3 Insert ball (1) and piston (2) into the housing.
008547
2-75
Throttle valve Ecomat HP 500 / HP 590
4 Screw cover (1) on tightly;

Tightening torque: 7 ft-lbs (9.5 Nm).
008548
5 Insert piston (1) as illustrated.
008549
6 Insert solenoid (1) and screw it on tightly;

7 Screw on cover (2) and gasket (3) tightly;

008550
2-76
Disassembly of hydraulic control unit, continued:
8 Unscrew M6 hex bolts (1).
008551
9 Remove complete fixing plate (1) for the inductive

sensor and cable harness.
10 Remove spacer rings (2).
008552
11 Unscrew the NBS (Neutral at Bus Stop) pressure

limiting valve from Block “B”.
008553
2-77
12 Remove the screw plug together with sealing ring

(1) and piston with pressure spring (2) from
pressure limiting valve (3).
008554
13 Unscrew twelve M6 hex bolts (1).
14 Remove valve block “A” (2).
008556
15 Unscrew M6 hex bolts from valve block “B”.
16 Remove valve block “B”.
008555
2-78
17 Remove the intermediate plate.
18 Use a plastic mallet to drive converter safety valve

(1) into the duct plate until the snap ring is
accessible.
19 Unclip snap ring (2).
20 Remove the converter safety valve.
008557
2-79
9.3.3 Disassembly of valve block for brake “F”,

lock-up clutch and clutches “C” and “A”.
1 Loosen cover plate (1) by tapping with a plastic

mallet. Remove the cover plate from the valve
block.
2 Remove the gasket.
CAUTION
Do not use a narrow-bladed tool to lever off the cover
plate. This can cause damage to its sealing surface.
008558
3 Remove valve ball (1) from the lock-up clutch duct.
008559
4 Unscrew eight M6 hex bolts (1).
5 Press cover plate (2) against the valve block and

unscrew hex bolt (3).
6 Remove the cover plate and its gasket.
! DANGER
Cover plate is under spring pressure. Release
this pressure carefully when removing the cover
plate.
008560
2-80
7 Mark the installation positions of pressure

springs (1).
8 Remove pistons (2) and pressure springs from the

valve block.
CAUTION
Do not switch over the pressure springs.
A spacer may be fitted in any of the various pistons.
Make sure the spacer from any one piston stays with its
respective piston.
Do not swap over any pistons which do have spacers.
008561
9 Unscrew and remove fifteen M6 hex bolts (1).
CAUTION
Do not remove hex bolt (2) from the valve strip.
10 Press cover plate (3) against valve strip (4).
11 Unscrew and remove hex bolt (2) and remove cover

plate.
! DANGER
plate.
008562
12 Remove the gasket from the valve strip.
2-81
13 Remove the valve strip from the valve block.
14 Remove pressure springs (1) from the control

pistons.
008563
15 Pull pressure springs (1) and vent pistons (2) out of

the valve strip.
008565
16 Remove bushes (1) complete with O-rings (2) from

the valve strip.
17 Remove control pistons (3) from the valve strip.
18 Remove O-ring (4) from the valve strip.
008564
2-82
19 Remove pistons (1) from valve block (2).
20 Remove stop washers (3) from the valve block.
008566
2-83
9.3.4 Disassembly of valve block for clutch “B”

and brakes “E”, “D” and “G”.
1 Loosen cover plate (1) by tapping it with a plastic

mallet.
2 Remove the cover plate from the valve block and

remove its gasket.
CAUTION
Do not use a narrow-bladed tool to lever off the cover
plate. This can cause damage to its sealing surface.
008567
3 Unscrew seven M6 hex bolts (1).
4 Press cover plate (2) against the valve block and

unscrew hex bolt (3).
5 Remove the cover plate.
! DANGER
plate.
008568
6 Remove the gasket.
7 Pull pistons (1) out of the valve block.
CAUTION
A spacer may be fitted in any of the various pistons.
Make sure the spacer from any one piston stays with its
respective piston.
Do not swap over any pistons which do have spacers.
008569
2-84
8 Mark the installation positions of pressure

springs (1).
9 Remove the pressure springs from the valve block.
CAUTION
Do not switch over the pressure springs.
008570
10 Unscrew and remove fifteen M6 hex bolts (2).
CAUTION
Do not remove hex bolt (1) from the valve strip.
008571
11 Press cover plate (3) against the valve strip.
12 Unscrew and remove hex bolt (1) and remove them

together with the shackle.
! DANGER
plate.
008572
2-85
13 Remove cover plate (1) and gasket (2).
008573
14 Remove valve strip (2) from the valve block.
15 Remove pressure springs (1) from the control

pistons.
16 Pull pressure springs (3) and the vent pistons out of

the valve strip.
008574
17 Remove bushes (1) complete with O-rings (2) from

the valve strip.
008575
2-86
18 Remove control pistons (1) from the valve strip.
19 Remove O-ring (2) from the valve strip.
008576
20 Remove pistons (1) and stop rings (2) from the

valve block.
008577
2-87
9.4 Assembly of hydraulic control unit.
NOTE: Check the duct plate for damage and replace it

if necessary.
1 Insert the converter safety valve into the duct plate.
2 Clip snap ring (1) onto the converter safety valve.
008578
3 Push the converter safety valve down until the snap

ring is firmly located in the duct plate.
4 Place the cover plate on the duct plate.
008579
2-88
9.4.1 Assembly of valve block for brake “F”,

lock-up clutch and clutches “C” and “A”
NOTE: Check the valve block for damage.
1 Check orifices (1, 2, 3, 4) to make sure the seats are

in perfect condition.
2 Check the orifice bore diameter using plug gage

1P01 137 173. Replace the orifices if necessary.
008580
3 If necessary, knock out the orifices using punch

1X56 137 156.
CAUTION
Sharpen the punch point before knocking out the
orifices.
008581
4 Insert new orifices and peen them using punch

1X56 137 151.
NOTE: Always peen new orifices twice, at 90° internal.
008582
2-89
5 Insert four stop washers (1) into the valve block

with their collars pointing downwards.
6 Insert four pistons (4) into the valve block as

illustrated.
008583
NOTE: Prevent the pistons from falling out when

turning over the valve block.
7 Insert all pressure springs (1) for the “A”, “C”

clutches, lock-up clutch and “F” brake pistons.
8 Push in pistons (2) with or without spacers.
008584
CAUTION
Do not switch over any pistons with spacers or any
springs. In case of spring breakage, select a new spring
as listed in the spare parts catalogue.
A clutch
C clutch
WK clutch
F brake
9 If using a new spring, recheck the spring wire

diameter and spring length (unloaded).
10 Compare these measurements with the entries in the

Table of Springs. Refer to pages 1-18 / 1-19.
008585
2-90
11 Position new gasket (3).
12 Place cover plate (3) onto gasket, press against the

valve block and tighten by hand using M6x16 hex
bolt (1).
! DANGER
Hold the cover plate firmly until hex bolt (1) is
screwed in.
008586
13 Tighten eight M6x16 hex bolts (1);

008587
14 Screw M6 threaded pins 1X56 150 111 into the

duct plate as illustrated.
008588
2-91
15 Push valve block (1) onto the threaded pins.
16 Insert valve ball (2) for the vent valve into the lock-
up clutch duct.
CAUTION
Check the valve ball diameter is 0.197” (5 mm).
Replace if necessary.
008589
17 Position new gasket (1) with printed side upwards.
CAUTION
Ensure vent holes (2) are positioned over the vent
valves (3).
008590
18 Place cover plate (1) onto the valve block.
19 Fix the valve block in position using two M6 hex

bolts.
20 Unscrew the threaded pins.
21 Screw in and tighten the remaining hex bolts;

NOTE: Do not insert bolts in bores (2).
22 Screw threaded pins 1X56 150 111 into the valve

block.
008591
2-92
23 Insert pressure control piston (2) into the valve

strip.
24 Coat new O-ring (1) with Vaseline and insert into

the valve strip.
008592
25 Insert bushes (3) with their collars facing into the

valve strip.
26 Coat new O-rings (1) with Vaseline and insert into

bushes (2).
008594
27 Use threaded pins (2) to position valve strip (1)

against the valve block.
28 Fit four vent pistons (3) with one pressure spring

(4) each and insert vent pistons (3).
29 Insert pressure springs (5) for the control pistons.
008593
2-93
30 Place new gasket (1) onto valve strip.
008595
31 Push cover plate (1) onto threaded pins (2) and

position against valve strip.
32 Screw in M6x60 hex bolt (3) and tighten the cover

plate against the valve strip.
33 Unscrew threaded pins.
008596
34 Screw in M6x18 hex bolts (1) and four M6x60 hex

bolts (2);
008597
2-94
9.4.2 Assembly of valve block for clutch “B” and

brakes “E”, “D” and “G”.
NOTE: Valve block “B” is assembled in the same way

as valve block “A” as described in Section 9.3. Any
modifications are described below.
008598
1 Insert four stop washers.
2 Insert four pistons.
008599
3 Insert the pressure springs and pistons (with or

without spacers).
CAUTION
Do not switch over any pistons with spacers or any
springs. In case of spring breakage, select a new spring
as listed in the spare parts catalogue.
Further assembly proceeds identically as for valve block

“A”.
008600
2-95
4 Position new gasket (1) for NBS (Neutral at Bus

Stop).
NOTE: Use a special gasket for the NBS.
5 Screw on the cover plate;

Tightening torque 7 ft-lbs (9.5 Nm).
008601
6 Insert piston (1) and pressure spring (2) into the

NBS valve (3).
7 Insert new sealing ring (4) and tighten it using

screw plug (5).
008602
8 Position complete NBS valve (1) on the cover plate

of valve block “B” (2) and screw on tightly;
008603
2-96
9 Position valve strip (1) on the valve block.
10 Screw cover plate (2) with holes for the cable

harness shackle (3) onto the valve block “B”.
11 Screw in all M6 hex bolts;

008604
12 Place one spacer ring (1) onto valve block “A” and
“B”.
008605
13 Position fixing plate (1) for the inductive sensor as

illustrated.
008607
2-97
14 Screw on shackle (1) for the inductive sensor cable.
008608
15 Screw shackles (1) for the cable harness onto the

valve blocks.
008609
16 Insert solenoid valves into the valve strips.
17 Connect the flat-pin plugs to the valves.
18 Insert plug connection for inductive sensor into

shackle (1) and tighten bolts;
008610
2-98
19 Screw throttle valve (1) onto the duct plate.
20 Connect electrical cables (2) to the throttle valve.
008611
2-99
Retarder valve Ecomat HP 500 / HP 590
10 Removal and installation of retarder valve.

10.1 Removal of retarder valve.
Remove the oil pan, see Section 7.1
CAUTION
New housing (from serial no. 88196) must be equipped
with new retarder valve. The new retarder valve can also
be installed in older housings. Do not confuse the new
and old retarder valve when installing. Only replace as
complete set.
1 Unscrew M8 hex bolts (1) and remove solenoid

valve (2).
008612
2 Unscrew M8 hex bolts (1) and remove cover (2).
008613
3 Pull piston (1) out of the valve housing.
008614
2-100
Ecomat HP 500 / HP 590 Retarder valve
4 Remove pressure springs (1, 2) from the piston.
008616
5 Screw M18x1.5 threaded pin or bolt (3) into stop

(1).
6 Pull out stop (1) and bush (2) using a threaded pin
or bolt.
008615
7 Press both pistons (1, 2) out of the valve housing

using a screwdriver.
008617
2-101
8 Pull both pistons (1) apart and remove pressure

spring (2).
008618
2-102
10.2 Installation of retarder valve.
CAUTION
New housing (from serial no. 88196) must be equipped
with new retarder valve - see spec. list! The new retarder
valve can also be installed in older housings. Do not
confuse the new and old retarder valve when installing.
Only replace as complete set.
1 Insert pressure spring (1) into piston (2).
2 Insert piston (3) into piston (2).
008619
3 Insert the piston assembly fully into the valve seat

with the pressure spring and piston (1) pointing
outwards.
008620
4 Screw stop (1) onto an M18x1.5 bolt or M18x1.5

threaded pin and push in until the stop is fully
inserted.
5 Remove the threaded pin or bolt.
008621
2-103
6 Push new O-ring (1) onto bush (2).
7 Press the bush into the valve housing until the bush
is fully inserted.
NOTE: Ensure the holes (3) in the bush are pointing

vertically upwards.
008622
8 Check the play between the bush and cover is

between 0 and 0.004” (0 and 0.1 mm). Adjust as
follows:
9 Place a depth gauge against the housing face, press

bush (1) fully against stop and measure dimension
“A” to the face of the bush.
008623
11 Place a depth gauge against the shoulder of the

cover and measure dimension “B” to the cover
surface (e.g. height of shoulder).
12 Subtract dimension “B” from dimension “A”.
A - B = C = actual play between bush and cover.

B
001579
001579
2-104
13 Ensure dimension “C” is between 0 and 0.004” (0

and 0.1 mm).
Shims (1) are available in the following thicknesses:
0730 004 295 = 0.3 mm (0.012”)

0730 004 296 = 0.4 mm (0.016”)
0730 004 297 = 0.5 mm (0.020”)
0730 002 566 = 0.6 mm (0.024”)
0730 002 565 = 0.8 mm (0.030”)
0730 004 298 = 1.0 mm (0.040”)
008624
14 Check seal (1) for damage.
15 If required, break apart the old seal and push a new

seal onto piston (2).
NOTE: Push on seal with open side pointing to the base

of the piston.
16 Insert shims (3) with the same thickness as the

shims which were removed into the piston.
008625
17 Insert pressure springs (1, 2) into the piston.
18 Push the complete piston into the valve housing.
008626
2-105
19 Insert shim(s) (1) of correct thickness.
20 Insert new O-ring (2) into the cover.
NOTE: Coat O-ring with Vaseline.
008627
21 Push the cover into the valve housing bore.
22 Tighten M8x25 hex bolts (1);

008628
23 Insert new O-ring (1) into the solenoid valve.
NOTE: Coat O-ring with Vaseline.
008629
2-106
24 Tighten solenoid valve (1) using two M8x55 hex

bolts (2); Tightening torque: 17 ft-lbs (23 Nm).
Install hydraulic control unit, see Section 9.2.

Fit the oil pan, see Section 7.2.
008630
2-107
Output cover Ecomat HP 500 / HP 590

of output cover.
11.1 Removal of output cover/inductive sensor.
CAUTION
If the converter has been removed, screw lifting device
(1) 1X56 137 213 into the turbine shaft.
008631
1 Move the transmission to the installation position.
2 Unscrew two M6 hex nuts (1) and remove together

with their washers.
3 Remove cover (2).
008633
4 Pull off both cable connections using a pair of

pliers.
5 Unscrew inductive sensor (1) using a socket

wrench.
6 Remove the inductive sensor and shim(s).
CAUTION
One or more shims may remain in the output cover.
Ensure all of the shims are removed.
008632
2-108
Ecomat HP 500 / HP 590 Output cover
11.1.1 Installation of inductive sensor.
1 Rotate the output flange until a tooth (1) of the

planetary carrier gearing is visible through the
threaded bore.
008634
2 Calculate the specified distance ”a” 0.02 to 0.027”

(0.5 to 0.7 mm) between the inductive sensor
contact face and the gearing face as follows. 2
1
1 = Planetary carrier gearing
2 = Output cover
3 = Inductive sensor 3
4 = Shim
a 4
001566
005273
3 Push sliding ring (1) to approx. 0.20” (5 mm) from

the end of measurement rod 1P01 137 833.
008635
2-109
4 Push measurement rod 1P01 137 833 into the

inductive sensor bore until the end of the
measurement rod touches the surface of the
gearing.
NOTE: Ensure that the measurement rod is introduced

at a right angle to the planetary carrier profile teeth.
008636
5 Carefully remove the measurement rod.
6 Measure dimension “b” from the end of

measurement rod to the sliding ring.
7 Note down dimension “b”.
008637
2-110
8 Measure dimension “c” from the contact surface of

the inductive sensor to the contact surface for the
spacer ring(s).
9 Subtract dimension “b” from dimension “c”.

c-b=d
10 Note down dimension “d”.

d+a = thickness “S” of the shim.
CAUTION
The figures given in the example below are theoretical.
Sample calculation:
b = 0.936” (24 mm) 008638

c = 1.014” (26 mm)
a = 0.02” to 0.027” (0.5 to 0.7 mm)
d=c-b
d = 1.014” - 0.936” (26 mm - 24 mm)
d = 0.078” (2 mm)
S=d+a
S = 0.078” + 0.02 to 0.027”
(2 mm + 0.5 to 0.7 mm)
S = 0.098 to 0.106” (2.5 to 2.7 mm)
Shims are available in 0.008” (0.2 mm) steps from

0.023” (0.6 mm) to 0.118” (3.0 mm).
See Section 8.2, Page 2-65, working step 15.
008640
11 Screw in inductive sensor (1) and spacer discs;

Tightening torque: max. 37 ft-lbs (50 Nm).
008639
2-111
12 Connect both cable connections (1) to the inductive

sensor using a pair of flat-nosed pliers.
NOTE: You do not have to observe polarity when re-

attaching the cable connections.
008642
13 Fit cover (2) with an O-ring and insert it into the

bore.
NOTE: Lightly oil the O-ring.
14 Screw on two M6 hex nuts (1) and washers;

008641
2-112
Removal of output cover, continued
15 Unscrew speedometer connection (1).
008643
16 Use a narrow-bladed instrument (e.g. chisel) to pry

off tab washer (1).
! DANGER
Wear protective eye glasses or goggles!
Metal chips may fly off.
008644
17 Unscrew two M12 hex bolts.
NOTE: Secure the output flange using a flange holder

in order to unscrew both hex bolts.
18 Remove thrust disc (1).
NOTE: If necessary, loosen the thrust disc by tapping it

lightly with a plastic mallet.
008645
2-113
19 Attach 2 or 3-arm pullers.
20 Insert pressure piece (1) and pull output flange (2)

off the output shaft.
CAUTION
Never use 2 or 3-arm pullers without a pressure piece.
Otherwise, the output shaft thread may become
damaged.
NOTE: Secure the flange with a flange holder when

pulling off.
008646
21 Swing the transmission so the output shaft points

upwards.
22 Screw lifting device 1X56 136 260 firmly onto the

output shaft. Unscrew all M10 hex bolts from
around the edge of output cover.
NOTE: Make sure the cable connections for the

inductive sensor have been removed.
See steps 2-4 on page 2-108.
008647
23 Attach lifting equipment to the output cover and

carefully lift the output cover off the transmission.
24 Remove gasket (1).
25 Remove lifting device 1X56 136 260.
CAUTION
Thread cable (2) for the inductive sensor carefully
through the housing bore.
008648
2-114
11.2 Installation of output cover.
1 Remove spacer disc (1) from sun gear (2).
NOTE: Spacer disc (1) may also be in the planetary

carrier.
008650
NOTE: A new output cover with new breather valve (1)

(ref. no. 4139 203 085) was introduced into production 1
2
from transmission no. 094884.
CAUTION
A new gasket (2) (ref. no. 4139 301 618) must be used
in conjunction with the new breather valve (1).
NOTE: The new gasket (ref. no. 4139 301 618) can also
be used for the old output cover version.
005550
2 Put on new gasket (1).
3 Set up measurement equipment (measurement

blocks (2) and measurement bar (3)) onto the
housing sealing face.
2-115
Output cover / Sun gear Ecomat HP 500 / HP 590
11.2.1 Measurement of end play of sun gear.
1 Measure and note down dimension “A” from the

measurement bar to the spacer disc contact surface
on the sun gear.
008651
2 Measure and note down dimension “M” from the

measurement bar to the gasket.
3 Subtract dimension “M” from dimension “A” to

calculate theoretical dimension “C” from the gasket
to the spacer disc contact face.
A-M=C
008652
4 Measurement of output cover dimension: use a

depth gage to measure dimension “B” from the
measurement bar to the spacer disc contact face.
Note down dimension “B”.
5 Calculate the thickness “X” of the spacer disc to

install as follows:
CAUTION
Ensure the height of the measurement equipment for
measuring dimension “B” is the same as for measuring
dimension “A” and “M”.
008653
2-116
Ecomat HP 500 / HP 590 Output cover / Sun gear
M-B=D
C-D=E
X = E - (0.023 to 0.031” / 0.6 to 0.8 mm)

0.023 to 0.031” (0.6 to 0.8 mm) = end play of spacer
disc.
CAUTION
The measurements given in the example are purely
theoretical.
Sample calculation:
A = 1.81” (46 mm)

B = 1.57” (40 mm)
M = 1.63” (41.5 mm)
This gives:
A-M=C
1.81” - 1.63” = 0.18” (46 mm - 41.5 mm = 4.5 mm)
M-B=D
1.63” - 1.57” = 0.06” (41.5 mm - 40 mm = 1.5 mm)
C-D=E
0.18” - 0.06” = 0.12” (4.5 mm - 1.5 mm = 3.0 mm)
X = E - 0.023 to 0.031” (E - 0.6 to 0.8 mm)

X = 0.12” - 0.023 to 0.031” (3,0 mm - 0.6 to 0.8 mm)
X = 0.086 - 0.094” (2.2 to 2.4 mm)
The spacer disc thickness may vary between 0.086 to

0.094” (2.2 and 2.4 mm).
Spacer discs are available in 0.008” (0.2 mm) steps.
0730 103 362 = 1.8 mm (0.071”)

0730 103 279 = 2.0 mm (0.078”)
0730 103 278 = 2.2 mm (0.086”)
0730 103 277 = 2.4 mm (0.094”)
0730 103 276 = 2.6 mm (0.102”)
0730 103 275 = 2.8 mm (0.110”)
0730 103 274 = 3.0 mm (0.118”)
0730 103 273 = 3.2 mm (0.125”)
0730 103 272 = 3.4 mm (0.133”)
CAUTION
Do not grind down spacer discs to achieve the correct
thickness. The spacer discs must be centered.
2-117
6 Attach spacer disc (1) of the calculated thickness to

the planetary carrier (2) using Vaseline.
008654
7 Screw lifting device 1X56 136 260 (1) firmly onto

the output shaft.
8 Attach lifting equipment to the output cover and

suspend above the transmission. Line up the output
cover with threaded pins (2).
008656
9 Slowly lower the output cover.
10 Whilst lowering the output cover, thread cable (1)

for the inductive sensor through hole (2) in the
output cover.
11 Lower the output cover fully and remove lifting

equipment.
CAUTION
When lowering the output cover, ensure the planet gears
engage in the gearing of the disc carrier, ring and sun
gear. You may have to rotate the output shaft slightly to
achieve this. Take care not to damage the inductive
sensor cable.
008655
2-118
12 Screw in fourteen M10x55 hex bolts (1).
13 Screw in two M10x75 hex bolts (2).
14 Tighten opposite pairs of hex bolts, working round

output cover until it is fully tightened onto the
transmission.
15 Fully tighten the hex bolts;

NOTE: Leave both bores (3) for the retarder

accumulator mountings free.
16 Unscrew lifting device 1X56 136 260.
008657
17 Coat the sealing face of thrust disc (1) with sealing

compound and place onto output flange.
18 Screw in two M12x30 hex bolts (2). Secure the

output flange with a flange holder to prevent it from
turning.
Tightening torque of hex bolts: 44 ft-lbs (60 Nm).
NOTE: Attach the thrust disc with its chamfered edge

pointing outwards.
008659
19 Use punch 1X56 136 471 to fit a new tap washer

onto the hex bolts.
20 Drive the tab washer onto the hex bolts.
008658
2-119
NOTE: If the speedometer connection leaks, fit a new

sealing ring as follows:
21 Push tapered adapter (1) onto the speedometer

shaft.
2 1 3
22 Coat the external diameter of shaft sealing ring (2)
with sealing compound.
23 Fill the area behind the sealing lip with grease.
24 Use adapter 1X56 100 632 (3) to push the sealing

ring over the tapered adapter (ensure the sealing
001578
ring sealing lip is pointing towards the pinion. Drive
the sealing ring into the speedometer connection.
001578
25 Coat the thread of speedometer drive (1) with oil.
26 Push new copper sealing washer (2) onto the

speedometer drive.
27 Screw in the speedometer drive;

28 Check that you can feel the tooth backlash of the

speedometer pinion by hand (0.004 to 0.008” /
0.1 to 0.2 mm).
29 Fit inductive sensor, see Section 11.1.1.

Install retarder accumulator, see Section 2.3.
Fit oil cooler, see Section 3.3.
008660
2-120
11.3 Dismantling output cover
NOTE: A new output cover with new breather valve (1) 2*

1
(item no. 4139 203 085) was introduced into production
from transmission no. 094884. The old output cover
with old breather valve (2*) (ref. no. 0768 360 015) was
installed in transmissions up to no. 094883.
1 New version: Loosen valve (1) by lightly tapping

with plastic hammer on output cover. Remove valve
from valve bore.
1.1 Old version: Unscrew breather valve (2*) and set

aside together with O-ring and copper seal.
005554
2 Place the output cover on the output flange.
3 Grip F piston (1) using a pair of pliers and drive the

F piston out of the output cover by striking the
output cover with a plastic mallet.
NOTE: When striking the F piston, spread the mallet

blows evenly around the circumference of the piston.
008661
4 Place the output cover on supports under a press so

the planetary carrier can be pressed out.
! DANGER
Do not hold the underside of the planetary
carrier.
5 Press the planetary carrier out of the output cover.
CAUTION
Place cushioning material underneath the planetary
carrier.
008662
2-121
6 Press the shaft seal out of the output cover.
NOTE: The shaft seal is easier to remove if you drive it

in on one side and lever it out using assembly irons.
7 Remove tapered roller bearing (1) from the output

cover.
8 Heat output cover to approx. 185 °F (85 °C) using

hot air blower 1X56 136 513.
008663
! DANGER
Put on protective gloves before touching the
heated output cover.
9 Use a plastic rod to drive out both bearing outer

rings (1).
NOTE: Always insert the plastic rod in grooves (2).

Drive the input bearing outer ring out from the output
end, drive the output bearing outer ring out from the
input end.
008665
10 Remove spacer disk (1) from speedometer worm

(2).
008664
2-122
11 Place extractor 1X56 126 464 onto the speedometer

worm.
CAUTION
Take care not to damage the speedometer worm gearing
when attaching the extractor.
12 Attach a 2-arm puller to the slots in the extractor.
CAUTION
Position pressure piece (1) on the end of the output
shaft.
13 Pull the speedometer worm off the output shaft.
008666
14 Pull spacer bush (1) off the output shaft.
15 Push grip 1X56 136 706 onto the tapered roller

bearing inner race.
16 Tighten the extractor edge with the threaded ring

until it grips the base of the tapered roller bearing.
008668
17 Screw base tool 1X56 122 306 onto grip

1X56 136 706.
18 Pull off tapered roller bearing inner race.
008667
2-123
19 Insert inner extractor 1X56 122 205 into the

bearing bore and attach extractor edge under the
base of the needle bearing.
20 Screw counter bracket 1X56 122 227 onto the inner

extractor.
21 Pull needle bearing (1) out of planetary carrier III.
008669
22 Release planetary gear pins (1).
! DANGER
Wear protective glasses when releasing the
planetary gear pins.
008670
23 Stand planetary carrier III on supports.
24 Drive out planetary gear pins (1).
008671
2-124
25 Remove planetary gears (1) out of the planetary

carrier III.
26 Remove two roller bearings (1) out of each

planetary gear.
008672
27 Remove two thrust washers from each planetary

gear.
NOTE: 2 or 3-hole thrust plates may also be fitted.
008673
NOTE: There are several different versions of planet

carrier III.
Version shown in figure: 2

Planet carrier III with thrust plates (3) and planet gear
axles (2) secured with slotted pin. 1
Loosening planet gear axles:

- Drive in slotted pins (1) to middle of planet gear
axles using suitable drift.
Never drive in slotted pins to limit of travel.
- Remove planet gear axles (2) from planet carrier
and drive out slotted pins from bore. 3
Dismantling planet carrier III:

- As described under Steps 25 to 27.
004836
2-125
11.4 Assembly of output cover.
1 Stand planetary carrier III with its output shaft

pointing downwards and secure it to stop it tipping
over.
2 Insert bottom thrust washers (1) or thrust plates.
008675
CAUTION
If using 2 and 3-hole thrust plates, note that these are bi-
metallic plates. Each has one steel and one aluminium
surface. The steel surface is marked (1) and must be the
side which touches the planetary carrier.
008674
3 Insert two roller bearings (2) into each planetary

gear (1).
CAUTION
Never replace individual planetary gears, only complete
sets.
NOTE: Grease the bearing surface of the planetary

gears and roller bearings with Vaseline before
installation.
008676
2-126
4 Insert complete planetary gear (1) and bearings into

the planetary carrier III.
5 Insert top thrust washers (2) or thrust plates.
CAUTION
surface. The steel surface is marked and must be the
008677
6 Line up the bearings, thrust washers (or thrust

plates) and planetary gear with the bores in the
planetary carrier.
7 Drive in planetary gear pin (1) until level with the

planetary carrier surface.
NOTE: Install the other planetary gears using the same

method.
008679
8 Place support 1X56 137 464 under a press.
9 Place the planetary carrier onto the support.
CAUTION
Ensure pin (1) engages with the holes for the planetary
gear pins.
008678
2-127
10 Place punch 1X56 137 466 under the press.
11 Press open the collar edges to secure the planetary

gear pins.
CAUTION
Always ensure that the planetary gear pin being secured
is braced against the support pin.
NOTE: There are several different versions of planet 008680
carrier III
Version shown in figure:

Planet carrier III with thrust plates (3) and planet 2
gear axles (2) secured with slotted pin (1).
1
Reassembly of planet carrier III secured with
slotted pin:
- As described under Steps 1 to 6.
Securing planet gear axles with slotted pin:

- Align bores for slotted pins and push planet gear
axles securely onto planet carrier. 3
- Drive new slotted pins (1) fully into planet gear
axles (2) on planet carrier and secure by peening
(2 x 180°).
004836
12 Measure the end play of planetary gears between

the thrust washer and planetary carrier.
NOTE: Permitted end play is 0.02 to 0.05”

(0.5 to 1.2 mm).
Measure on all the planetary gears.
008681
2-128
13 Drive a new needle bearing into planetary carrier III

using rod 1X56 137 101.
NOTE: Using rod 1X56 137 101 gives the correct

installation dimension for the needle bearing. Place rod
against the bearing edge which has the stronger collar.
Oil the needle bearing before installation.
008682
11.4.1 Adjustment of tapered roller bearing.
1 Clamp adjustment device 1P01 136 816 in a vice.
NOTE: Wash both tapered roller bearings and apply a

thin coat of oil to them.
008684
2 Push tapered roller bearing output inner race (1)

onto the adjustment device.
3 Drive hollow tension pins (2) approx. 5 mm out of

the adjustment ring in advance.
4 Push the spacer bush and adjustment ring (3) onto

adjustment device 1P01 136 816.
CAUTION
Ensure hollow tension pins (2) are protruding upwards.
008683
2-129
5 Heat output cover to approx.185 °F (85 °C) using

hot air blower 1X56 136 513.
6 Insert bearing input outer race (1) into the output

cover with broader collar pointing upwards. Use
inserter 1X56 136 824 to drive the bearing outer
ring (1) in fully.
! DANGER
Put on protective gloves before touching the heated
output cover.
008685
7 Turn over output cover.
8 Install bearing output outer race (1) as described in

working step 6.
CAUTION
Make sure the bearing outer rings do not cool below
185 °F (85 °C) before they are installed.
008687
9 Place output cover on adjustment device

1P01 136 816.
Ensure the output cover is seated evenly.
10 Insert tapered roller bearing output inner race (1).

Make sure the bearing race is evenly seated.
008686
2-130
11 Position disc (1) of the adjustment device with its

recess pointing towards the adjustment device.
12 Screw M12 hex bolt (2) fully in.
NOTE: The temperature of the adjustment device

components must be approx.68°F (20°C) for the
following adjustment procedure.
Specified bearing adjustment

= 0.002 to 0.006" (0.05 to 0.15 mm) preload
This equates to a bearing rolling torque of

1.3 ft-lbs to 4.7 ft-lbs (1.8 to 6.4 Nm) at ambient
temperature.
008688
13 Wrap a cord several times around the neck of the
output cover. Connect the end of the cord to a
spring balance.
14 Exert an even tension on the spring balance until

the output cover starts to turn. Check that the force
required to do this is between 3.3 and 4.4 lbs
(15 and 20 N).
15 Tighten the hex bolt if the force required is less

than 3.3 lbs (15 N).
CAUTION
If the hex bolt is tightened too much, e.g. the force
required is above 4.4 lbs (20 N), dismantle the complete
adjustment device and start the measurement process
again.
008689
16 Loosen hex bolt (1) and remove the disc.
17 Remove the output cover from the adjustment

device.
CAUTION
Take care not to move the tension pins when loosening
the hex bolt.
008690
2-131
18 Remove the adjustment ring.
19 Lay the adjustment ring on a flat surface with the

tension pins pointing downwards.
20 Use a depth micrometer to measure dimension “A”

from the top edge of the adjustment ring to the
bottom edge of the tension pins.
008691
21 Use a depth micrometer to measure dimension “B”

for the speedometer worm (1) in the same way.
Note down dimension “B”.
22 Subtract dimension “B” from dimension “A”. The

result is dimension “C”.
Calculate the thickness “S” of the shim to fit as

follows:
S = C + 0.002” (0.05 mm)
0.002” (0.05 mm) = constant addition factor
008693
23 Check calculated thickness of the shim to be fitted

using a micrometer.
Shims are available in the following thicknesses:
0730 103 586 = 1.20 mm 0.047”

0730 103 587 = 1.10 mm 0.043”
0730 106 668 = 1.05 mm 0.041”
0730 103 588 = 1.00 mm 0.041”
0730 106 667 = 0.95 mm 0.037”
0730 106 666 = 0.90 mm 0.035”
0730 103 589 = 0.80 mm 0.031”
0730 103 590 = 0.60 mm 0.023”
0730 103 591 = 0.40 mm 0.015”
008692
2-132
24 Heat output tapered roller bearing inner race (1) to

185°F (85°C) using hot-air blower 1X56 136 513.
Push the bearing inner race fully onto the output
shaft.
CAUTION
Never heat the rollers. Install bearing with its narrow
taper pointing towards the output.
25 Push spacer bush (2) onto the output shaft.
008694
26 Heat speedometer worm (1) to 185°F (85°C) using

hot-air blower 1X56 136 513. Push the speedometer
worm onto the output shaft.
CAUTION
Install speedometer worm with collar pointing towards
the output.
008695
27 Once the parts have cooled, press on the toothed

disc, bearing inner race and speedometer worm
using inserter 1X56 136 824. Make sure all parts
are pressed on fully.
008696
2-133
28 Slide on shim (1) of the calculated thickness.
008697
29 Place the output cover on the planetary carrier.
30 Heat output bearing inner race (1) to 185°F (85°C)

using hot-air blower 1X56 136 513.
31 Insert the bearing inner race into the output cover

until it is evenly seated.
008698
32 Coat the outer edge of shaft sealing ring (1) with

lubricant.
1
33 Push the shaft sealing ring onto inserter
1X56 136 824 with the shaft sealing ring sealing lip
pointing towards the output cover.
008699
2-134
34 Use a press and inserter 1X56 136 824 to press the

shaft sealing ring fully into the output cover.
35 Using inserter 1X56 136 824 automatically sets the

correct clearance of 0.6 -0.04 inch (15 -1 mm)
between the top of the bearing inner race and the
top of the sealing ring.
CAUTION
Fill the sealing lip and disc lip of the shaft sealing ring
with non-acidic grease.
008700
NOTE: Insert the connection bolts for the propshaft

flange (if appropriate) before fitting the output flange.
36 Heat output flange (1) to approx. 230°F (110°C)

using hot-air blower 1X56 136 513.
37 Press the output flange fully onto the output shaft.
NOTE: If you cannot push the output flange on fully

although it is heated to the specified temperature, place
the planetary carrier on support 1X56 137 154.
Push on the output flange fully using a mandrel press.
008701
38 Coat the sealing face of thrust disc (1) with sealing

compound and place onto output flange.
NOTE: Attach the thrust disc with its chamfered edge

pointing outwards.
39 Smear bolt heads of the M12x30 hex bolts on their

underside with sealing compound (WEVO-L100
produced by WEVOCHEMIE), screw in and
tighten. Secure the output flange with a flange
holder to prevent it from turning.
NOTE
Always use new hex bolts here.
008659
2-135
“NBS”F brake Ecomat HP 500 / HP 590
40 Use punch 1X56 136 471 to fit a new tap washer

onto the hex bolts.
41 Drive the tab washer onto the hex bolts.
! DANGER
When the lock plate (1) has been driven in, you
may be left with a sharp edge. Carefully remove
this edge using a file or other suitable tool.
NOTE
Let output cool down to ambient temperature.
008658
42 Re-check bearing rolling torque. Wrap a cord

several times around the neck of the output cover.
Connect the end of the cord to a spring balance.
43 Exert an even tension on the spring balance until

the output cover starts to turn. Check that the force
required to do this is between 3.3 and 4.4 lbs
(15 and 20 N). This equates to a bearing rolling
torque of 1.3 ft-lbs to 4.7 ft-lbs (1.8 to 6.4 Nm) at
ambient temperature.
CAUTION
If bearing rolling torque is not within the specified
tolerance range, adjustment needs to be corrected.
015824
11.4.2 Setting of disc play in brake “F” and “NBS”.
1 Place gasket (1) onto the housing sealing face.
NOTE: In the version without NBS, the final disc is an

outer disc. Measure dimension "A" using a depth gauge
positioned on this outer disc (not illustrated).
2 Use a depth gauge to measure from the

measurement bar to the outer edge or highest point
of plate spring (2). Note down dimension “A”.
008702
2-136
Ecomat HP 500 / HP 590 “NBS”F brake
3 Use a depth gauge to measure from the

measurement bar to the gasket. Note down
dimension “B”.
4 B - A = C Note down dimension “C”.
008703
5 Insert the F piston into the output cover. Ensure the

F piston is evenly seated.
6 Use a depth gauge to measure from the output cover

sealing face (without gasket) to the F piston contact
surface. Note down dimension “D”.
7 Disk play = D - C
The disc play must be between 0.13 to 0.15” (3.2
and 3.7 mm). Set using the outer discs. Discs are
available in the following thicknesses.
0.08” 0.10” 0.12” (2.0 mm 2.5 mm 3.0 mm)
CAUTION
Do not use the F piston end disc for setting the disc play.
008704
8 Set NBS (Neutral at Bus Stop) by gripping F piston

(1) with a pair of pliers. Hit around the edge of the
output cover using a plastic mallet.
9 Remove the F piston.
008705
2-137
“NBS”F brake Ecomat HP 500 / HP 590
10 Insert outer lip sealing ring (1) into the F piston.

Make sure the sealing lip is facing the pressure
side.
11 Insert lip sealing ring (2).
12 Insert the inner lip sealing ring.
008707
13 Adjustment device for NBS.
008706
14 Place adjustment device 1P01 137 906 onto the F

piston with the “Piston Side” downwards (see
markings). Loosen fixing bolts (1) on the
adjustment device.
15 Press rings (2) of the adjustment device against the

piston and carefully tighten the fixing bolts.
008709
2-138
Ecomat HP 500 / HP 590 “NBS” F brake
16 Place spring elements into transmission housing

without springs.
008708
17 Place the adjustment device “Disc Side” down onto

the disc pack plate spring. Check the adjustment
device is centered and the holes are lined up with
the spring elements.
008710
18 Insert measurement tubes into the adjustment

device. Set each spring element using a Torx
screwdriver so the top of each measurement tube is
level with the outer ring of the adjustment device.
008711
2-139
"NBS" F brake Ecomat HP 500 / HP 590
19 Check the adjustment made in working step 18

using a straight-edge.
008712
20 Lift off the adjustment device. Position the F piston

and place the adjustment device onto the F piston
for improved measurement accuracy.
008713
21 Check the NBS end play using a feeler gauge

between the F piston and plate spring.
Permissible play is 0.002 to 0.01”

(0.05 to 0.25 mm).
008714
2-140
Ecomat HP 500 / HP 590 Mechanical transmission section
12 Removal and installation of mechanical

transmission section.
12.1 Removal of mechanical transmission section.
1 Remove cable (1) for the inductive sensor from the

transmission.
008715
2 Pull off sun gear (1) from the input shaft.
008717
3 Remove thrust washer (1) from input shaft.
NOTE: The thrust washer may also be stuck to the base

of the sun gear.
008716
2-141
Mechanical transmission section Ecomat HP 500 / HP 590
4 Remove the springs and spring elements for NBS.
008718
5 Use assembly hooks 1X56 097 775 to remove

planetary carrier II (1) from the transmission.
! DANGER
The assembly hooks do not hold the planetary
carrier stably
008720
6 Remove disc pack (1) for the F brake from the

transmission.
CAUTION
Mark the disc pack accordingly. Do not switch discs
between different disc packs.
008719
2-142
7 Remove thrust washer (1) from the transmission.

of planetary carrier II.
008721
8 Remove pressure springs (1), pins (2) and guide

tubes (3) from the transmission.
008722
2-143
Planetary carrier II Ecomat HP 500 / HP 590
12.1.1 Disassembly of planetary carrier II
1 Use a screwdriver to unclip retaining ring (1) at all

four access points (2).
CAUTION
Make sure the retaining ring does not snap back into its
ring groove.
008723
2 Pull off the output ring gear (1) from planetary

carrier II (2). Remove the retaining ring.
NOTE: If required, use a plastic mallet to separate the

ring gear from planetary carrier II.
008724
3 Use a suitable punch to release planetary gear pins

(1).
! DANGER
008725
2-144
Ecomat HP 500 / HP 590 Planetary carrier II
4 Use a punch to drive planetary gear pins (1) down

out of planetary carrier II.
5 Remove planetary gears (2) from planetary

carrier II.
008726
6 Remove roller bearings (1) from each planetary

gear.
008727
7 Remove thrust plates (1) from planetary carrier II.
NOTE: Remove 3-hole thrust plates first.
008728
2-145
8 Use a suitable pin to press retaining ring (1) out

through hole (2).
9 Use a screwdriver to lever out the retaining ring.
10 Place a plastic rod against the shoulder (arrowed) of

ring gear (3).
11 Drive the ring gear off planetary carrier II.

See Section 12.1.3, working step 3.
008729
2-146
12.1.2 Assembly of planetary carrier II.
1 Insert lower thrust plates (1).
008730
CAUTION
surface. The steel surface is marked (1) and must be the
008731
2 Insert two roller bearings (2) in each planetary gear

(1).
NOTE: Apply Vaseline to the bearing bore of the

planetary gears and to the roller bearings before
installation.
008732
2-147
3 Insert complete planetary gear (1) and bearings into

the planetary carrier II.
4 Insert top thrust washer (2) with its steel side facing
the planetary carrier.
008733
5 Line up the bearings, thrust washers and planetary

gear with the holes in the planetary carrier.
6 Drive in planetary gear pin until level with the

CAUTION
Always use new planetary gears.

method. Always replace planetary gears in complete
sets.
008734
7 Place support 1X56 137 464 under a press.
8 Place the planetary carrier (1) onto the support.
9 Place punch 1X56 137 466 under the press. Press

open the collar edges to secure the planetary gear
pins.
008735
2-148
CAUTION
Ensure pin (1) engages with the holes for the planetary
gear pins. Always ensure that the planetary gear pin
being secured is braced against the support pin.
008736
10 Measure end play of planetary gears between the

thrust washer and planetary carrier using a feeler
gauge.
NOTE: Permitted end play is 0.02 to 0.05” (0.5 to

1.2 mm). Measure on all the planetary gears.
008738
11 Place output ring gear (1) under a press with its ring
groove pointing upwards.
12 Place planetary carrier II (2) onto the ring gear.
13 Line up the planetary carrier and ring gear gearing.
14 Place a suitably sized pressure piece onto the

planetary carrier.
15 Press the ring gear onto the planetary carrier.
008737
2-149
16 Clip in retaining ring (1).
CAUTION
Insert the retaining ring so that its separation is adjacent
to the hole (2). Ensure the retaining ring is fully inserted
into the ring groove.
008739
17 Place planetary carrier II under a press.
18 Position retaining ring.
19 Place input ring gear (1) on the planetary carrier

with its ring groove pointing towards the planetary
carrier.
20 Place an appropriately sized pressure piece onto the

planetary carrier.
21 Press the ring gear onto the planetary carrier. Stop

pressing on before the retaining ring binds.
008741
22 Use a screwdriver to clip the retaining ring into the

ring groove in the ring gear.
23 Press ring gear on fully. Use a screwdriver to press

retaining ring (1) into the ring groove at all access
points (2).
CAUTION
Insert the retaining ring so the ring join is located at one
of the access points (2). Ensure the retaining ring is fully
clipped into the ring groove.
008740
2-150
Removal of mechanical transmission section,

continued:
24 Use assembly hooks 1X56 097 775 to remove

planetary carrier I from the transmission.
! DANGER
The assembly hooks do not hold the planetary
carrier stably.
008743
25 Remove thrust washer (1) from the transmission.

of planetary carrier I.
008742
12.1.3 Disassembly of planetary carrier I.
1 Use a suitable pin to press retaining ring (1) out

through hole (2).
2 Use a screwdriver to lever out the retaining ring.
008744
2-151
3 Place a plastic rod against the shoulder of ring gear

and drive the ring gear off the planetary carrier.
008745
4 Use a suitable punch to release planetary gear

pins (1).
! DANGER
5 Use a punch to drive planetary gear pins (1) down

out of planetary carrier I.
008746
6 Remove planetary gears (1) and thrust washers (2)

by pushing them towards the center of planetary
carrier I.
7 Remove the needle bearing from the planetary

gears.
008747
2-152
Ecomat HP 500 / HP 590 Planetary carrier I
12.1.4 Assembly of planetary carrier I.
1 Insert lower thrust plates (1) into planetary carrier I

with curved profile pointing outwards.
CAUTION
The thrust plates are bi-metallic plates. Each has one
steel and one aluminium surface. The steel surface is
marked (1) and must face the planetary carrier.
008748
2 Insert needle bearing (2) into each planetary

gear (1).
NOTE: Coat the bearing bore of the planetary gears and

the needle bearings with Vaseline.
008750
3 Insert complete planetary gear and bearings into the

planetary carrier I.
4 Insert top thrust washer (1) with its steel side facing
the planetary carrier.
008749
2-153
Planetary carrier I Ecomat HP 500 / HP 590
5 Line up the bearings, thrust washers and planetary

gear with the holes in the planetary carrier.
6 Drive in planetary gear pin (1) until level with the

CAUTION
Always use new planetary gears.
Always replace planetary gears in complete sets.

method.
008751
7 Place support 1X56 137 464 under a press. Place

planetary carrier (1) onto the support.
8 Place punch 1X56 137 466 under the press. Press

open the collar edges to secure the planetary gear
pins.
CAUTION
Ensure pins (2) engage with the holes in the planetary
gear pins. Always ensure that the planetary gear pin
being secured is braced against the support pin.
008752
9 Measure end play of planetary gears between the

thrust washer and planetary carrier using a feeler
gauge.
CAUTION
Do not measure at the recess.
NOTE: Permitted end play is 0.02 to 0.05” (0.5 to 1.2

mm). Measure on all the planetary gears.
008753
2-154
Ecomat HP 500 / HP 590 Planetary carrier I
10 Place ring gear (1) under a press with its ring

groove pointing upwards.
11 Place planetary carrier I (2) onto the ring gear.
12 Line up the planetary carrier and ring gear gearing.
13 Place a pressure piece onto the planetary carrier.

Press the ring gear onto the planetary carrier.
008755
14 Clip in retaining ring (1).
CAUTION
Insert the retaining ring so that its ends are adjacent to
the hole (2). Ensure the retaining ring is fully inserted
into the ring groove.
008754
2-155

continued:
1 Turn pressure ring (1) until the pressure ring teeth

(2) are lined up with the tooth profile (3) of the
transmission housing.
008756
2 Remove pressure ring (1) from the transmission.
3 Take disc pack (2) out of the transmission.
CAUTION
Mark the disc pack accordingly. Do not switch discs
between different disc packs.
4 Leave centring pins (3) standing on the last disc.

Lift out the centring pins carefully, for example by
lifting them out with the last disc.
! DANGER
Make sure the centring pins do not fall into the
transmission.
008758
5 Remove E piston (1) from the transmission

housing.
008757
2-156
NOTE: If the E piston binds: blow compressed air in

through one of the oil ducts (1). This will loosen the E
piston.
! DANGER
Cover the transmission housing with a large rag
before using compressed air to loosen the
E piston. Protect eyes against oil spray.
008759
6 Remove lip sealing rings (1) from the E piston.

1
1
008760
7 Lift disc carrier (1) out of the transmission.
008761
2-157
8 Remove needle bearing (1) and thrust washer (2)

from the input shaft.
NOTE: Needle bearing (1) and thrust washer (2) may

also be attached to the base of the disc carrier.
008762
9 Remove top needle bearing (1) from the disc

carrier.
008763
2-158
12.1.5 Removal of sun gear from disc carrier.
1 Use a screwdriver to unclip the outer and inner

retaining rings.
2 Rotate the inner and outer retaining rings so one of

the ring ends is visible in groove (1).
3 Use a suitable rod to drive sun gear (2) out of the

disc carrier.
008764
12.1.6 Installation of sun gear in disc carrier.
1 Insert sun gear (1) into the disc carrier with its
longer collar uppermost.
2 Drive in the sun gear fully until it is evenly seated.
008765
3 Insert the inner and outer retaining rings into the

ring groove.
NOTE: Turn each retaining ring so that the ring ends

are lined up with access point (1).
008766
2-159

5 HP 500:
4 Lift the quill shaft out of the transmission housing.
NOTE: Remove the quill shaft by turning it until its

gearing lines up with the inner discs of the B and C
clutches.
008768
5 Remove both needle cages.
6 Remove the thrust washer from the input shaft or

quill shaft.
008769
Installation of mechanical transmission section,

5 HP 500:
7 Attach the thrust washer to the quill shaft using

Vaseline and place both needle cages onto the quill
shaft.
8 Line up the inner discs of B and C clutches using a

screwdriver.
9 Insert the quill shaft into the transmission housing.
008767
2-160

continued:
1 Remove input shaft (1) from the transmission.
008770
2 Remove thrust washer (1) from the turbine shaft.
NOTE: The thrust washer may be attached to the input

shaft.
008772
3 Insert inner extractor 1X56 122 205 into the

bearing bore. Grip underneath the needle bearing.
008771
2-161
4 Screw counter bracket 1X56 122 227 onto the inner

extractor.
5 Tighten counter nut (1) by hand and pull the needle

bearing out of the input shaft.
008773
2-162
12.2 Installation of mechanical transmission section.
1 Use punch 1X56 137 101 to drive a new needle

bearing into the input shaft. Make sure the needle
bearing is evenly seated.
NOTE: Using punch 1X56 137 101 ensures that the

needle bearing installation dimension is correct.
Drive the punch against the side of the bearing with a
reinforced edge.
008774
2 Attach thrust washer (1) to the input shaft using

Vaseline.
008775
3 Line up and center outer discs (1) of the A clutch

using a screwdriver.
008776
2-163
4 Insert input shaft (1).
CAUTION
Ensure the input shaft is evenly seated.
5 Place thrust washer (2) onto the input shaft.
NOTE: Coat the thrust washer with Vaseline.
NOTE: For 5 HP 500 transmission, install the quill

shaft.
008777
6 Coat output needle bearing (1) with Vaseline and

insert into sun gear (2).
008779
7 Coat lower needle bearing (1) with Vaseline and

insert into sun gear (2).
008778
2-164
8 Place complete disc carrier (1) onto the input shaft.
CAUTION
Take care the lower needle bearing is not displaced.
Make sure the disc carrier is evenly seated. If necessary,
carefully rotate the disc carrier to achieve this.
008783
9 Insert inner (1) and outer (2) lip sealing rings into
the E piston.
CAUTION
Check the lip sealing rings and replace if necessary. Fit
the lip sealing rings with their grooves pointing towards
the pressure side. Stretch the inner lip sealing ring
before installing it to make sure it fits into the groove
properly (e.g. flush with base of groove).
008782
10 Coat the E piston sealing faces and lip sealing rings

lightly with Vaseline.
11 Insert E piston (1) into the transmission as

illustrated. Carefully drive in the E piston using a
plastic mallet until it is evenly seated.
CAUTION
Take care not to damage the lip sealing rings when
installing the E piston. The E piston should be a tight
fit.
008781
2-165
12 Measure the 1st outer disc of the E brake.
CAUTION
The 1st outer disc of the E brake is 0.12” (3 mm) thick.
13 Check outer and inner discs for wear.
008784
14 Use a straight-edge to check that all discs are flat.
15 Discard uneven or bowed discs. Also discard

damaged discs.
CAUTION
There is a 1st and 2nd version of the E brake. In the 1st
version, the first 0.12” (3 mm) thick outer disc which is
inserted has holes in it. The lower pins for this version
are shorter than those in the F brake.
In the 2nd version and NBS version, the first 0.12”
(3 mm) thick outer disc has no holes. In this version, the
lower pins are the same length as those in the F brake.
NOTE: Follow steps 16 to 18 A), B) or C) as 008785

appropriate when inserting the E brake discs. A) is for
the first version, B) is for the second version and C) is
for the NBS version.
A) First version
Mark the positions of the housing bores which are cast
more deeply into the housing (see arrow).
16A Insert the first outer disc so the holes (2) in the
outer disc line up with the deeper housing bores.
17A Insert an inner disc.
18A Insert the second outer disc with the “gaps” in its
tooth profile positioned over the holes in the first
outer disc.
008786
2-166
B) Second version
Mark the positions of the housing holes which are cast
more deeply into the housing (see arrow).
16B Insert the first outer disc so the middle tooth (2) of
each group of three teeth lines up with deeper
housing holes which were marked in advance (see
arrow).
17B Insert an inner disc.
18B Insert the second outer disc with the “gaps” in its
tooth profile positioned over each middle tooth (2)
of the groups of three teeth in the first outer disc.
008789
C) NBS version
16C Insert the first outer disc so the middle tooth (2) of
each group of three teeth lines up below the spaces
for the spring elements (3).
17C Insert an inner disc
18C Insert the second outer disc with the “gaps” in its
tooth profile positioned over each middle tooth (2)
of the groups of three teeth in the first outer disc.
19 Insert the remaining discs in the correct sequence.
NOTE: Refer to the spare parts list for details of the

outer and inner discs.
008787
20 Insert the pressure ring. Ensure the notches around

the outside of the pressure ring are positioned
correctly for installing the spring elements.
21 Lift the pressure ring slightly and turn it until its

teeth slide under the projections of the housing
profile.
22 Measure the E brake disc play using a feeler gage.
NOTE: The disc play must be 0.12 to 0.14” (3.0 to 3.5

mm) (HP 590) or 0.10 to 0.12” (2.5 to 3.0 mm) (HP
500). Correct the disc play by fitting a final outer disc
with a different thickness.
NOTE: Remove pressure ring and complete disc pack
from the transmission again.
008788
2-167
23 Use Vaseline to attach thrust washer (1) to the disc

carrier.
008790
24 Use assembly hooks 1X56 097 775 to lower

planetary carrier (1) into the transmission.
! DANGER
Also support planetary carrier I using other
assistance to make sure it does not slip off the
assembly hooks.
25 Install the E brake disc pack as already described.
CAUTION
Make sure the first outer disc is the 0.12” (3 mm) disc.
008792
CAUTION
Insert the pressure ring with round notches (1) lined up
with the housing holes.
26 Insert two spring elements (2) to fix the pressure

ring.
008791
2-168
27 Use Vaseline to attach thrust disc (1) to the input

end of planetary carrier II.
008793
28 Turn over planetary carrier II. Use assembly hooks

1X56 097 775 to lower planetary carrier (1) into the
transmission.
! DANGER
Also support planetary carrier I using other
assistance to make sure it does not slip off the
assembly hooks.
CAUTION
Make sure the thrust washer on the input side does not
fall off the planetary carrier.
008794
29 Use Vaseline to attach the thrust washer to the input

contact surface of the sun gear.
NOTE: The input contact surface of the sun gear has

two machined recesses.
30 Push sun gear (1) onto the input shaft.
31 If required, drive the sun gear fully on by tapping

lightly with a plastic mallet.
008795
2-169
32 Check outer and inner discs for wear. Check

evenness of all discs using a straight-edge.
Discard all uneven or bowed discs. Also discard all
damaged discs. (See also the description in
Section 5.3.4).
008796
33 Measure and fit the F clutch discs.
NOTE: Refer to the Spare Parts List for the number of

inner and outer discs.
008798
34 Insert inner and outer discs in alternate sequence.
CAUTION
Insert the outer discs with the gaps (1) between the
driver lugs lined up with the pressure springs (2).
NOTE: The final outer disc does not have any holes in
it and has larger engagement lugs.
008797
2-170
35 NBS (Neutral at Bus Stop)

Place angle ring and plate spring in position.
008799
36 Insert the gasket for the output cover onto the

008801
37 Insert cable (1) for the inductive sensor into the

CAUTION
Make sure you thread the inductive sensor cable through
the correct housing duct.
Fit the output cover, see Section 11.2.
008800
2-171
12.2.1 Measurement and adjustment of inductive

sensor ring.
1 Set the transmission so its base is pointing upwards.
2 Maximum concentricity error of inductive sensor

ring is + 0.008” (0.2 mm). The concentricity error
refers to the protrusions on the inductive sensor
ring. Correct errors by tapping carefully with a soft
hammer.
(4-speed version)
- Install hydraulic control unit, see Section 9.2.

- Install oil pan, see Section 7.2.
- Install oil cooler, see Section 3.3.
- Install retarder accumulator, see Section 2.3.
2-172
Ecomat HP 500 / HP 590 Control unit

of control unit.
2
13.1 Removal of control unit. 1
NOTE: Step 1 only applies for transmissions with new

housing (from transmission no. 97173). 3
1 Loosen M8 hex bolts (1). Remove hex bolts and

securing plate (2) for suction pipe (3).
005548
2 Use inner extractor 1X56 122 208 and counter

bracket 1X56 122 227 to pull suction tube (1) out
of the transmission housing.
008802
3 Remove O-ring (1) from suction tube (2).
008803
2-173
Control unit Ecomat HP 500 / HP 590
4 Fix the transmission with its input end pointing

upwards.
5 Unscrew M8 cap screws (1) from around the

circumference. Remove cap screws and washers.
CAUTION
Use inner hex head driver 1X56 137 273 to remove cap
screws around the circumference. Take care not to
damage the cover plate sealing surface.
008804
6 Connect lifting equipment to lifting device

1X56 137 213.
7 Use hot air blower 1X56 136 513 to heat the

transmission housing around the control unit to
approx. 185 °F (85 °C).
! DANGER
008806
8 Lift the control unit out of the transmission housing

and place it on wood blocks.
! DANGER
Do not remove lifting device 1X56 137 213,
otherwise the turbine shaft will fall downwards
through the control unit.
008805
2-174
13.2 Installation of control unit
1 Line up the hole pattern of the intermediate ring (1)

with the hole pattern of the control unit.
NOTE: Make sure the lug (arrowed) of the intermediate

ring engages with the notch in the sealing ring.
(See Section 13.4).
2 Insert two cap screws to assist centring.
008808
3 Screw M8 guide bolts 1X56 136 821 into the

transmission housing to assist centring.
4 Screw lifting device 1X56 137 213 onto the turbine

shaft.
008807
5 Use hot air blower 1X56 136 513 to heat the
interference fit for the control unit in the
transmission housing to approx. 185 °F (85 °C).
6 Use lifting equipment to suspend the control unit

above the transmission. Line up the control unit
with the guide bolts and lower it into the
transmission.
NOTE: Ensure the control unit is evenly seated straight-

away.
! DANGER
008809
2-175
7 Unscrew guide bolts.
8 Screw five M8x65 cap screws (1) into the control

unit.
008811
9 Screw in M8x55 cap screw.
10 Screw in M8x70 cap screw.
008810
11 Attach control unit to housing bore using two M8

bolts and wide intermediate plate or wide washers
(see arrow), ensuring there is zero play.
CAUTION
Non-conformance with these help measures may lead to
leakages on the transmission.
NOTE:
– This help measure prevents a drop in lubrication
pressure.
– Use wide intermediate plate.
– Do not damage sealing face.
003140
2-176
12 Tighten all socket head screws (1/2/3) using driver

1X56 137 273.
CAUTION
Do not damage sealing faces when screwing in and
13
2
11
3
tightening socket head screws.
003 598
13 Unscrew the M8 bolts required for the help measure

(step 11) and remove together with intermediate
1
plate.
003598/003597
14 Grease O-ring (1) with technical vaseline and place

in transmission housing.
1
003 599
003599
15 Grease suction pipe (1) with technical vaseline and

place in transmission housing. 4
3
NOTE: If the suction pipe is difficult to position, 2
carefully drive in using plastic hammer.
16 Position securing plate (2) with two M8x18 hex 1

bolts (3) for securing suction pipe.
17 Secure each hex bolt (3) with securing plate shackle

(4).
NOTE: Steps 16 and 17 only apply to transmissions

with new housing (from transmission no. 97173).
005548
2-177
13.3 Disassembly of control unit.
1 Unscrew lifting device 1X56 137 213 from the

turbine shaft.
CAUTION
When unscrewing the lifting device, hold the turbine
shaft to prevent it from falling down.
2 Lower the turbine shaft through the control unit

until retaining ring (1) is accessible.
3 Use circlip pliers to remove the retaining ring.
008812
4 Lift turbine shaft (1) out of stator quill shaft (2).
008813
5 Screw hooks 1X56 136 612 into the control unit.
6 Attach lifting equipment.
7 Lift the control unit slightly off its base.
8 Use rod 1X56 137 109 to separate the clutch carrier

from the control insert.
9 Remove the clutch carrier and lower the control

insert.
! DANGER
Never hold the clutch carrier from underneath
when separating it from the control insert.
008814
2-178
13.3.1 Disassembly of control insert.
1 Hold spacer ring (1) and pull out cylindrical pin (2).
2 Remove spacer ring.
! DANGER
The spacer ring is spring-loaded.
008815
3 Remove the pressure spring.
4 Take piston (1) for the cooler change-over valve out

of the valve housing.
008816
5 Push clamping device 1X56 137 108 onto the

control insert.
6 Screw the clamping device spindle into the

converter back-up pressure valve.
008817
2-179
7 Unload the retaining rings using the spindle.
8 Use circlip pliers to remove retaining ring (1).
9 Unscrew the spindle and remove sealing washer (2)

and retaining ring (1).
! DANGER
Sealing washer is spring-loaded. Ensure the
sealing washer does not jump out when
unscrewing the spindle.
NOTE: Remove main pressure valve (3) in the same

sequence.
008818
NOTE: A „P 3.1“ repair set (ref. no. 4139 298 987) can
be obtained from ZF Friedrichshafen AG for the main
pressure valve P2 (3), which is fitted as standard during
production. If, during the transmission lifetime, the
main pressure drops when the converter clutch is
disengaged, this can be rectified using this service
solution without the need to remove the transmission.
- See Service Memo no. 11/94 .-
10 Remove pressure spring (1) and piston (2) of the

converter back-up pressure valve from the housing
bore.
008819
11 Screw fixture 1X56 137 107 into the spacer ring.
12 Hold the fixture and spacer ring and remove

cylindrical pin (1).
13 Pull out the spacer ring using fixture

1X56 137 107.
! DANGER
Spacer ring is spring-loaded.
008820
2-180
14 Push piston (1) of the lubricating pressure valve

forwards using a screwdriver. Pull out the piston
and pressure spring.
! DANGER
The housing has sharp edges. Never insert
unprotected fingers into the housing.
008822
15 View of all valves and pressure springs.
CAUTION
There are various versions of the main pressure valve.
See spare parts list or spec. list and Service Memo no.
11/94 for further procedure.
008821
16 Press out plug (1) for pressure line using two

screwdrivers.
CAUTION
Do not damage the control insert sealing face.
17 Remove O-ring (2) for the suction tube.
008823
2-181
18 Turn over the control unit.
19 Place pressure piece 1X56 137 104 onto the oil feed
flange.
008824
20 Insert extractor device 1X56 122 322 into grooved

ball bearing (1) and clamp on using the ring.
21 Pull the grooved ball bearing off the oil feed flange.
NOTE: Use 46 mm AF open-jawed wrench to brace the

extractor check-nut (2).
008825
22 Remove four rectangular rings (1) which have

intersecting ends.
008826
2-182
NOTE: Remove rectangular rings with intersecting ends

as follows:
Press one end of the rectangular ring into the base of the
groove using your thumb.
Slide your index finger around the ring until the
connection releases.
001582
001582
! DANGER
The rectangular rings have sharp edges. Always
use a rag or protective gloves to prevent the risk
of injury when removing rectangular rings.
008827
23 Unscrew and remove all M8 hex bolts (1) from the

oil feed flange.
008828
2-183
24 Remove spring guide (1) together with pressure

springs (2), cup springs (3) and guide pins (4) from
the stator ring.
! DANGER
Prevent the springs from jumping out.
CAUTION
The spring guide pins are fitted with 48 cup springs
each. Ensure that the spring guide pins do not jump out.
008829
25 Remove pressure spring (1), spring guide (2) and

cup springs (3) from guide pin (4). Spring seat (5)
may be attached to the pressure spring.
008831
26 If necessary, remove spring seat (1) from the stator

ring.
008830
2-184
27 Turn over the control insert.
28 Unscrew M8 cap screws (1).
008832
29 Use inner hex head driver 1X56 137 273 to unscrew

cap screw (1) from primary pump (2).
008833
30 Lift the control insert off the oil feed flange.
008834
2-185
31 Screw two M8 hex bolts (1) into the stator quill

shaft at 180° to each other.
32 Lightly tap hex bolts (1) using a plastic mallet to

loosen the stator quill shaft.
008835
33 Unscrew the hex bolts from the stator quill shaft.
34 Remove stator quill shaft (1) from the control

insert.
NOTE: The two clamping pins can remain installed.
008837
35 Remove rectangular ring (1).
008836
2-186
NOTE: Remove rectangular rings with intersecting ends

as follows:
Press one end of the rectangular ring into the base of the
groove using your thumb.
Slide your index finger around the ring until the
connection releases.
001582
001582
! DANGER
The rectangular rings have sharp edges. Always
use a rag or protective gloves to prevent the risk
of injury when removing rectangular rings.
1
36 Unclip rectangular ring (1) using a screwdriver.
003161
003161
37 Insert extractor 1X56 137 432 into the ring groove

in the piston ring carrier.
38 Place pressure piece (1) onto the stator quill shaft.
39 Attach 2-arm pullers and grip behind extractor

1X56 137 432.
40 Pull the piston ring carrier off the stator quill shaft.
41 Remove extractor and pressure piece.
42 Remove needle cage (2).
008838
2-187
43 Check bearing inner race (1) for damage. If

necessary, replace it together with the needle cage.
44 Attach extractor plate 1X56 124 659 to the bearing

inner race with its stamped numbers pointing
upwards.
45 Screw in both M8 hex bolts evenly.
CAUTION
Ensure the stamped figures on each half of the extractor
plate are lined up.
008839
46 Place pressure piece (1) onto the stator quill shaft.
47 Place the stator quill shaft and extractor plate under

a press and press the bearing inner race off the
stator quill shaft.
008841
48 Check the bush and rectangular rings in the stator

quill shaft for damage.
49 If necessary, drive out the bush using punch

1X56 136 820.
CAUTION
Only remove the bush if it is damaged.
008840
2-188
NOTE: The bush and rectangular rings represent a

complete component.
001583
001583
CAUTION
Do not hit the primary pump.
50 Place the complete control insert on supports

approx. 4” (100 mm) in an industrial oven. Heat to
approx. 300 °F (150 °C).
51 Heat the control unit until the primary pump falls

out under its own weight.
NOTE: Place the control insert in the oven with the

primary pump input gear pointing upwards.
008842
52 Unscrew three M8 cap screws (1) from the rear of

oil feed flange (2).
53 Remove the cap screws and washers.
008843
2-189
54 Turn over the oil feed flange.
55 Remove thrust ring (1).
56 Lift stator ring (2) out of the oil feed flange.
008844
2-190
13.3.2 Assembly of control insert.
1 Place stator ring (1) into the oil feed flange so the
vanes overlap.
2 Place thrust ring (2) into the stator ring and line up
with the threaded holes.
NOTE: Make sure the recess in the thrust ring is

pointing towards the stator ring.
You should be able to turn the stator ring easily.
008845
3 Turn over the oil feed flange.
4 Fit M8 cap screws with washers. Screw in M8 cap

screws; Tightening torque: 12 ft-lbs (16 Nm).
008846
5 Place the oil feed flange onto

support 1X56 136 818.
6 Place control insert (1) onto oil feed flange (2) and
line up with the holes.
008847
2-191
7 Fit three M8x70 cap screws (1) with one washer

each. Screw in the cap screws until hand-tight.
008848
8 Fit four M8x55 cap screws (1) with one washer

each. Screw in the cap screws until hand-tight.
008849
9 Fit M8x40 (1) and M8x45 (2) cap screws with one
washer each. Screw in the cap screws until hand-
tight.
10 Tighten all cap screws to 17 ft-lbs (23 Nm).
008850
2-192
11 Screw guide bolt 1X56 136 821 into the hole for the
primary pump bolt.
003 638
003638
12 Place the control insert in an industrial oven and

heat to 300 °F (150 °C).
13 Push primary pump (1) over the guide bolt and

install in the pump seat.
! DANGER
heated control insert.
008851
CAUTION
The primary pump will fall into the pump seat by itself
if the control insert is heated to the correct temperature.
Never hit the primary pump. Ensure the primary pump
is evenly seated.
14 Remove the guide bolt.
15 Fit M8x40 cap screw with a washer. Screw in the

cap screw until hand-tight.
NOTE: Wait until the control insert has cooled to room

temperature and then screw the cap screws in tightly;
2-193
NOTE: The bush and rectangular rings (1) is a

complete component.
001583
001583
16 Use hot-air blower 1X56 136 513 to heat the stator

quill shaft to approx. 300 °F (150 °C).
NOTE: Line up the hole in the bush with the hole in the
stator quill shaft.
17 Insert the bush into the stator quill shaft. Make sure
the bush is evenly seated.
008853
18 Use hot-air blower 1X56 136 513 to heat the

bearing inner race to approx. 185 °F (85 °C).
19 Push the bearing inner race fully onto the stator

quill shaft.
! DANGER
heated bearing inner race.
008854
2-194
20 Oil needle cage (1) and push it onto the stator quill
shaft.
21 Use hot-air blower 1X56 136 513 to heat piston ring

carrier (2) to 185 °F (85 °C). Push on piston ring
carrier (2) until evenly seated.
! DANGER
piston ring carrier.
CAUTION
Do not hit the piston ring carrier.
008855
22 Clip the retaining ring into the stator quill shaft ring
groove.
23 Insert rectangular ring (1) into the piston ring

carrier. Clip the ends of rectangular ring (1)
together.
CAUTION
Ensure the piston ring is inserted correctly and its ends
are clipped together.
008857
24 Center the stator quill shaft on clamping pins (1).
25 Drive on the stator quill shaft fully until it is evenly

seated by hitting lightly with a plastic mallet.
! DANGER
Allow the control insert to cool before installing
the stator quill shaft.
008856
2-195
26 Turn over the control insert.
27 Fit M8x45 hex bolts (1) with washers. Screw the

hex bolts into the stator quill shaft;
008858
28 Insert the four rectangular rings (1) in sequence.
NOTE: Always insert the lowest rectangular ring first.

Ensure the ring ends are correctly clipped together.
CAUTION
Do not break the rectangular rings. Ensure that all
rectangular rings are fully clipped into the ring groove.
008859
29 Use hot-air blower 1X56 136 513 to heat the

bearing bore of the oil feed flange to approx. 185 °F
(85 °C).
30 Insert grooved ball bearing (1) into the bearing

bore. Drive the grooved ball bearing fully on until
evenly seated by tapping it lightly around the
circumference with a plastic mallet.
! DANGER
Do not touch heated surfaces.
CAUTION
Ensure the grooved ball bearing remains level when
driving it on.
008860
2-196
31 Push the stator ring to open position and insert

spring seat (1).
008861
32 Fit spring guide pins (1) with 48 cup springs (2).
CAUTION
Always fit the cup springs in groups of six springs all
pointing in the same direction. Insert the next group of
six cup springs facing in the opposite direction, etc.
4 3 2 1
33 Put the spring guide (1) and pressure spring (2) over
guide pin (3) with cup springs. 1,6 ± 0,5
34 Measure the clearance between the spring guide and

guide pin.
35 The clearance must be 0.063 + 0.02” (1.6 + 0.5 mm).

If necessary, correct by adding more cup springs.
NOTE: Repeat this procedure for the other two spring

guides.
003831
2-197
36 Insert three complete pressure units (1) into the

stator ring.
CAUTION
Make sure the spring guide pins are exactly located on
the oil feed flange.
008862
CAUTION
Assemble and insert pistons for individual components
of the control insert extremely carefully and under
conditions of complete cleanliness.
NOTE: A „P 3.1“ repair set (item no. 4139 298 987)

can be obtained from ZF Friedrichshafen AG for the
main pressure valve „P2“ (3), which is fitted as standard
during production. If, during the transmission lifetime,
the main pressure drops when the converter clutch is
disengaged, this can be rectified using this service
solution without the need to remove the transmission.
- See Service Memo no. 11/94. -
37 Assemble the piston and springs for the main

pressure valve as illustrated.
008874
38 Insert complete piston (1) for the main pressure

valve into the control insert.
008863
2-198
39 Fit clamping device 1X56 137 108 to the control

insert.
40 Push ring (1) onto the spindle.
41 Insert new O-ring (2) into the spacer.
42 Apply a thin coat of Vaseline to the O-ring.
43 Place spacer against the main pressure valve piston.

Use the spindle screw to carefully press the spacer
and piston into the housing bore.
008865
44 Use the spindle screw to press the main pressure

valve piston approx. 0.16” (4 mm) behind the ring
groove for the retaining ring.
45 Insert ring (1) into the valve bore.
46 Insert retaining ring (2) and clip it into the ring

groove.
! DANGER
Before screwing the spindle, ensure that the
retaining ring is correctly clipped into the ring
groove.
47 Remove clamping device 1X56 137 108.

008867
48 Insert piston (1) for the lubrication pressure valve.
008866
2-199
Control unit HP 500 / HP 590
49 Insert pressure spring (1) into the lubrication

pressure valve piston.
008868
50 Screw the spacer ring onto fixture 1X56 137 107.
51 Use fixture 1X56 137 107 to push the spacer ring

into the lubrication pressure valve bore until it
reaches bore (1).
008869
52 Line up the hole in the spacer ring with the housing

bore (1).
008870
2-200
53 Insert the cylindrical pin into the bores.
54 Unscrew fixture 1X56 137 107 and remove it.
008871
55 Insert piston (1) and pressure spring (2) of the

converter back-up pressure valve into the valve
bore.
008872
56 Fix clamping device 1X56 137 108 onto the control

insert.
57 Place thrust washer (2) against the valve with its

crowned side pointing inwards. Clamp the thrust
washer lightly using the spindle.
58 Hang retaining ring (1) on the spindle.
008873
2-201
59 Press the thrust washer into the valve bore using the
spindle. Ensure the thrust washer goes in without
tilting.
60 Clip retaining ring (1) into the ring groove.
61 Unscrew the spindle and remove the clamping

device.
! DANGER
Ensure the retaining ring is fully clipped into
the ring groove before unscrewing the spindle.
008874
62 Insert piston (1) and pressure spring into the bore

for the cooler change-over valve.
008876
63 Insert spacer ring (2) into the valve bore.
NOTE: Line up the spacer ring and housing bores.
64 Insert cylindrical pin (1).
008875
2-202
65 Apply a thin coat of Vaseline to the new O-ring (2).
66 Insert O-ring (2) into plug (1) for the pressure line.
67 Insert the plug into the pressure line.
008877
2-203
Clutch carrier Ecomat HP 500 / HP 590
13.3.3 Disassembly of clutch carrier.
1 Remove intermediate ring (1) from the clutch

carrier.
! DANGER
The clutch carrier weighs approx. 55 lbs.
(25 kg). Two persons are required to move it.
008878
2 Unscrew and remove M8 hex bolts (1). Remove

rotor (2) from the clutch carrier.
008879
3 Remove sealing ring (1) from the clutch carrier.
4 Remove rectangular ring (2) from the sealing ring.
008880
2-204
Ecomat HP 500 / HP 590 Clutch carrier
5 Turn over the clutch carrier.
6 Place the insert of clamping device 1X56 137 127

into the clutch carrier. Lay the pressure plate on top
and screw on the handwheel.
7 Clamp the clutch carrier together by tightening the

handwheel.
008881
8 Release and unclip retaining ring (1).
NOTE: Tap the C piston lightly to assist in unclipping

the retaining ring.
9 Remove the retaining ring and C piston from the

clutch carrier.
008882
11 Remove clamping device 1X56 137 127.
12 Remove reverse gear pot.
13 Pull the O-ring out of the reverse gear pot.
008883
2-205
14 Lift the last outer disc off the clutch carrier.
008884
15 Remove pins (1) and springs (2) from the holes.
16 Lift the complete disk pack out of the clutch carrier.
008885
17 Use a bar magnet to draw out two torsional fixing

pins (1) from the clutch carrier.
008886
2-206
18 Turn end disc (1) so its teeth line up with the

recesses in the clutch carrier.
19 Lift out the end disc from the clutch carrier.
008887
20 Lift out complete disc pack (1) of the B clutch from

the clutch carrier together with pins (2).
21 Remove the pins from the discs.
008888
22 Use a pair of pliers to pull retaining pins (2) out

towards the inside.
23 Remove split rings (1).
24 Remove end disc (3).
008889
2-207
25 Lift out complete disc pack (1) of the A clutch from

the clutch carrier.
26 Remove the fixing plate and the cup spring.
008890
27 Turn over the clutch carrier and remove the C

piston.
28 Remove the inner lip sealing ring of the C piston.
008892
29 Remove the lip sealing ring from the clutch carrier.
008891
2-208
30 Place the clutch carrier on the lower section of

clamping device 1X56 137 127.
31 Place pressure piece 1X56 137 105 onto the

remaining plate spring (1).
32 Screw on the handwheel. Press the plate spring

down until you can unclip the snap ring.
33 Unclip the snap ring and slide it over the ring

groove together with the fixing plate.
NOTE: Position pressure piece 1X56 137 105 with its

opening facing the ring ends.
008893
34 Remove the pressure piece.
35 Remove snap ring (1) and fixing ring (2).
36 Remove cup spring (3) from the clutch carrier.
008894
37 Grip A piston (1) with a pair of pliers and loosen

the A piston by hitting the hub lightly with a plastic
mallet.
008895
2-209
38 Remove A piston (1) from the clutch carrier.
39 Remove outer lip sealing ring (2) from the A piston.
40 Remove inner lip sealing ring (3) from the A piston.
008896
41 Loosen B piston (1) by hitting the end of the clutch

carrier as illustrated. Remove the B piston.
008897
42 Remove outer lip sealing ring (2) from B piston.
43 Remove inner lip sealing ring (3) from the B piston.
008898
2-210
44 Attach inner extractor 1X56 122 209 underneath

the base of the needle bearing.
45 Screw counter bracket 1X56 122 227 onto inner

extractor 1X56 122 208.
46 Tighten check-nut (1) by hand.
47 Pull the needle bearing out of the bearing bore.
008899
48 Place the clutch carrier in an industrial oven and

heat to approx. 300 °F (150 °C).
49 Hit hub (1) with a plastic mallet to drive it out of

the clutch carrier.
! DANGER
heated clutch carrier.
008900
2-211
13.3.4 Assembly of clutch carrier.
1 Screw two guide bolts 1X56 136 821 into the clutch
carrier at opposite points.
2 Place the clutch carrier in an industrial oven and

heat to approx. 300 °F (150 °C).
Slide hub (1) over the guide bolts. Make sure the
hub is evenly seated and in the correct radial
position.
3 Unscrew guide bolts.
! DANGER
Put on protective gloves before touching the 008901
heated clutch carrier.
4 Insert the needle bearing into the hub. Drive in the

needle bearing fully using rod 1X56 137 103.
NOTE: Coat the needle bearing with Vaseline before

fitting it. Insert the needle bearing with the rod driving
against its stronger bearing side. The impact side of the
needle bearing is its written side.
008902
2-212
5 Insert A piston (1) into the clutch carrier without

fitting its lip sealing rings.
6 Place the cup spring without slots onto the A piston

so the edge of its bore is touching the piston.
7 Push the fixing ring over the plate spring with the
closed side of the fixing ring pointing upwards.
008903
8 Check outer (1) and inner (2) discs for wear.
9 Use a straight-edge to check all discs are flat.
10 Replace all uneven or bowed discs. Replace all

damaged discs also.
008905
11 Insert complete disk pack (1) of the A clutch into

the clutch carrier, starting with an inner disk.
NOTE: The last disk is an outer disk. Refer to the Spare

Parts Catalogue for the number of disks.
008904
2-213
12 Position end disc (1).
13 Insert split rings (2).
008906
14 Measure dimension “A” from the top of the hub to

the end disc.
008907
16 Lift and hold the end disc against the split ring.
17 Measure dimension “B” from the top of the hub to

the top of the lifted end disc.
19 Subtract dimension “B” from dimension “A” to

calculate the disc play.
008908
2-214
NOTE: A clutch disc play should be 0.12 to 0.14”

(3.2 to 3.7 mm).
20 Set the disc play using steel discs of different

thicknesses (0.08 to 0.10”) (2.0 to 2.5 mm).
21 Remove the complete disc pack, fixing ring and cup

spring from the clutch carrier again.
22 Remove the A piston from the clutch carrier.
23 Check the sealing rings on the B piston for damage

and replace if necessary.
24 Insert the sealing rings into the B piston ring

grooves.
NOTE: Ensure both sealing rings are firmly seated in

the base of the groove.
008909
25 Coat the sealing rings and B piston contact surfaces

with Vaseline.
26 Insert B piston (1) centrally into the clutch carrier

without tilting it.
27 Lightly hit the B piston with a plastic mallet to

ensure it is evenly seated.
CAUTION
Do not damage the sealing rings. The piston should be
a tight fit.
008910
2-215
28 Insert the outer and inner lip sealing rings into the
ring grooves in the A piston. Insert the sealing rings
with their grooves facing the pressure side.
NOTE: Stretch the inner lip sealing ring before

fitting it.
Ensure that both lip sealing rings are firmly located
against the base of the groove.
008911
29 Insert A piston (1) into the clutch carrier. Hit the A

piston lightly with a plastic mallet to ensure it is
evenly seated.
CAUTION
Coat the lip sealing rings and contact faces of the A
piston with Vaseline before installing the A piston. Take
care not to damage the lip sealing rings when installing
the A piston.
30 Place cup spring (2) onto the A piston so the

projections in the spring mesh with the projections
on the piston.
008912
31 Slide fixing ring (1) over the hub with its recess
pointing upwards.
32 Slide snap ring (2) over the hub.
008913
2-216
33 Place pressure piece 1X56 137 105 onto the cup

spring.
NOTE: Turn the pressure piece so the ends of the snap

ring are visible in the opening of the pressure piece.
34 Press the cup spring downwards using clamping

device 1X56 137 127.
35 First push fixing ring (1) over the ring groove and
then clip in snap ring (2).
CAUTION
Make sure the snap ring is clipped in all the way round.
008914
36 Check the inner and outer discs of the B and C

clutch for wear.
37 Use a straight-edge to check all discs for evenness.
38 Discard uneven or bowed discs. Discard damaged

discs.
See also the Test Instructions in Section 5.3.4.
008916
39 Lay first disc (1) of the B clutch in the clutch

carrier.
CAUTION
The first disc is an outer disc 0.12” (3 mm) thick. The
first disc does not have any gaps.
008915
2-217
40 Insert an inner disc (1) followed by an outer disc (2)

into the clutch carrier.
CAUTION
Insert the second and all other outer discs of the B
clutch so their recesses (3) line up with the holes (4).
Check that the 3 and 4-tooth groups for the discs are
lined up correctly.
41 Insert the complete disc pack. Ensure that outer and

inner discs alternate through the clutch carrier.
NOTE: Refer to the appropriate parts list for details of

which discs to fit.
008917
42 Insert the end disc and rotate it into position.
CAUTION
Insert the end disc so its hardened bores (1) are lined up
with the bores (2) with rectangular milled recesses in
the clutch carrier. Hardened bores are recognizable by
their sheen.
008919
43 Insert two retaining pins (1) into the bores with

rectangular groove (2).
008918
2-218
44 Use a feeler gage to measure the B clutch disc play

between the end disc and the last outer disc.
45 Measure the disc play several times around the

circumference.
NOTE: The disc play of the B clutch should be 0.08 to

0.10” (2.0 to 2.5 mm) (for HP 590) or 0.06 to 0,08” (1.6
to 2.1 mm) (for HP 500). Set the disc play using steel
discs of various thicknesses (0.08 and 0.10”) (2.0 and
2.5 mm).
008920
46 Place the cup spring without slots onto the A piston

with the edge of its bore in contact with the piston.
47 Slide the fixing disc over the cup spring with its
closed side pointing upwards.
008921
48 Insert the complete A clutch disc pack into the

clutch carrier.
CAUTION
The first disc is an inner disc and the last disc must be
an outer disc.
008922
2-219
49 Insert end disc (1) into the clutch carrier.
50 Insert split rings (2).
008923
51 Lift the end disc and insert three pins (1).
008925
4 speed version:
52 Insert pins into the pressure springs.
53 Insert pins and pressure springs into the clutch

carrier.
008924
2-220
54 Place the lower section of clamping device

1X56 137 127 into the clutch carrier.
55 Place the inductive sensor ring onto the clutch

carrier.
56 Line up the holes in the inductive sensor ring with

the holes in the clutch carrier. Insert two threaded
pins into the holes.
008927
57 Lay the plate of clamping device 1X56 137 127

over the lower section. Screw on the handwheel of
the clamping device and press the inductive sensor
ring down onto the clutch carrier.
58 Unscrew and remove the threaded pins. Fit the hex

bolts with washers and screw them into the holes in
the inductive sensor ring;
008828
5 speed version:
59 Check the C clutch discs according to the Test

Instructions in Section 5.3.4.
60 Insert the complete disc pack into the clutch carrier.
008926
2-221
61 Insert pins into the pressure springs.
62 Insert pins and pressure springs into the clutch

carrier.
008929
63 Insert lip sealing ring (1) around the outside of the

clutch carrier. Insert with its groove pointing
towards the pressure side.
008930
64 Place the last discs onto the pressure spring pins.

Ensure the last disc is an outer disc with a full set of
broad outer teeth.
008931
2-222
65 Place the clutch carrier onto the clamping fixture.
008932
66 Oil a new O-ring and insert it in the reverse gear

pot.
67 Locate the reverse gear pot on the clutch carrier so

its guide grooves snap over the guide lugs.
NOTE: Ensure the last outer disc does not slide off the
pressure springs.
008934
68 Use the clamping fixture to press together the

reverse gear pot and clutch carrier.
008933
2-223
70 Insert the inner lip sealing ring into the ring groove
in the C piston. Insert the lip sealing ring with its
groove pointing towards the pressure side.
NOTE: Stretch the inner lip sealing ring before

installing it.
Ensure the lip sealing ring is firmly seated against the
base of the groove.
71 Place the C piston into the reverse gear pot.
NOTE: Take care not to damage the lip sealing rings.

Insert the piston with a sliding fit.
008935
72 Clip snap ring (1) into the ring groove.
NOTE: Ensure the snap ring is firmly located against

the base of the ring groove around its entire circum-
ference.
008936
73 Measure the specified C clutch disc play using a

feeler gage between the outer disc and the reverse
gear pot. Measure disc play at several points around
the circumference and not the average value.
Disk play must be 0.06 to 0.08” (1.6 to 2.1 mm)
(HP 590) or 0.05 to 0.07” (1.2 to 1.7 mm) (HP
500). Set the disc play using discs of varying
thicknesses 0.08 and 0.10” (2.0 and 2.5 mm).
008937
2-224
4 and 5-speed version:
75 Place sealing ring (1) onto the clutch carrier.
76 Clip in rectangular ring (2) with the marking

“TOP” or “R” pointing upwards.
008938
77 Screw two guide bolts 1X56 136 821 into the clutch
carrier.
78 Line up rotor (1) with the bores and lower into

place.
NOTE: The irregular hole pattern of the rotor means it

can only be installed in one position.
008939
79 Unscrew the threaded pins.
80 Screw in eighteen M8x40 hex bolts (1);

008940
2-225
13.3.5 Clutch carrier leakage test and functional

check
1 Push insertion bush 1X56 137 128 into the clutch

carrier.
NOTE: Oil sealing rings (1) lightly before pushing in

the insertion bush.
008941
2 Screw knurled nut (1) onto the insertion bush and

tighten until the insertion bush is evenly seated.
3 Connect compressed air unit 1X56 137 130 to the

A, B or C piston connection.
4 Turn regulator (1) a few turns clockwise. 008942
5 Open the air flow by moving lever (2) to the

horizontal position. Set the maximum pressure to
43.5 psi (3 bar) using regulator (1).
6 Move lever (2) to the vertical position to cut off the

air supply. Measure the rate of pressure loss.
Maximum pressure loss is from 36 +7psi (2.5 + 0.5
bar) down to 20 psi (1.4 bar) within 10 seconds.
7 Remove the compressed air unit.
CAUTION
If the pressure drop at one piston is excessive, remove
the appropriate piston and correct the leak.
008943
2-226
13.4 Assembly of control unit.
1 Place intermediate ring (1) into position.
CAUTION
Ensure lug (2) on the intermediate ring meshes with
recess (3) in the sealing ring.
008944
2 Screw hooks 1X56 136 612 into the control insert

at opposite points.
008945
3 Attach lifting equipment to the hooks and suspend

the control insert over the clutch carrier.
4 Use hot air blower 1X56 136 513 to heat grooved

ball bearing (1) to approx. 185 °F (85 °C).
! DANGER
Do not touch the heated grooved ball bearing.
008946
2-227
5 Lower control insert (1) onto clutch carrier (2).
6 Hit the control insert lightly with a plastic mallet to

drive it fully onto the clutch carrier.
7 Insert O-ring (3) for the suction tube in the control

unit. Check the O-ring.
008947
8 Remove the lifting equipment and insert turbine

shaft (1) into the control unit.
008948
CAUTION
Check that none of the three pins (1) are protruding
through into hub (2) before sliding in the turbine shaft.
008949
2-228
9 Push in the turbine shaft until the ring groove is

accessible.
10 Clip retaining ring (1) into the turbine shaft ring

groove.
11 Screw lifting device 1X56 137 213 into the turbine

shaft.
CAUTION
Take care not to damage the oil tube when lifting the
control unit.
008950
12 Place supports under the control unit so it does not

rest on the turbine shaft.
- Fit the control unit, see Section 13.2, page 2-175.
008951
2-229
D brake Ecomat HP 500 / HP 590
14 Removal and installation of D brake.
14.1 Removal of D brake.
1 Use two screw clamps to press end disc (2) parallel

against the stop.
2 Unclip retaining ring (1) using a screwdriver.
008952
3 Unscrew the clamps evenly and remove them.
4 Remove end disc (1) from the transmission.
! DANGER
Loosen the screw clamps evenly because the
end disc is spring-loaded.
008953
5 Remove pressure springs (1) and pressure pins.
6 Lift complete disc pack (2) out of the transmission

housing.
008954
2-230
Ecomat HP 500 / HP 590 D brake
7 Cover the transmission housing with a cloth.
8 Loosen D piston (1) by blowing in compressed air

through one of the oil ducts (2).
008957
9 Lift D brake piston (1) out of the transmission

housing.
008955
10 Remove outer and inner lip sealing rings (1, 2) from

the D piston.
008956
2-231
14.2 Installation of D brake.
1 Insert the inner lip sealing ring into the D piston

with its groove pointing towards the pressure side.
! DANGER
Check the lip sealing rings for damage before
installing them. Fit new lip sealing rings if
necessary.
2 Insert the outer lip sealing ring into the D piston

with its groove pointing towards the pressure side.
NOTE: Coat the outer and inner lip sealing rings lightly
with Vaseline.
008958
3 Insert D piston (1) into the transmission housing.
4 Hit the D piston lightly with a plastic mallet to

make sure it is evenly seated.
CAUTION
Do not damage the lip sealing rings.
008960
5 Check the outer and inner discs for wear.
6 Use a straight-edge to check all discs for evenness.
7 Discard uneven or bowed discs. Discard all

damaged discs.
See also the Test Instructions in Section 5.3.4.
008959
2-232
Ecomat HP 500 / HP 590 D brake
8 Insert first outer disc (1).
CAUTION
Insert the outer disc so one of the disc bores (2) is lined
up with the arrowed recess in the housing.
008961
9 Insert pressure pins (1) in the outer disc bores.
10 Place pressure springs onto the pressure pins.
11 Insert an inner disc (2).
008962
12 Place the next outer disc (1) so the gap between the
teeth (2) lines up with the pressure springs.
13 Insert inner and outer discs in alternative sequence

until the complete disc pack is installed.
NOTE:The last disc is an outer disc. Refer to the Spare

Parts Catalogue for the number of discs.
008963
2-233
14 Lay on end disc (1).
CAUTION
Insert the end disc with its twin-stepped surface
pointing upwards.
008964
15 Insert two screw clamps and press the end disc

parallel against the block.
16 Clip retaining ring (1) into the ring groove.
17 Remove the screw clamps.
! DANGER
Check that the retaining ring is fully clipped in
around the entire length of the ring groove
before taking off the screw clamps.
008965
18 Measure disc play of „D“ brake between end shim

and last outer disc using depth gauge.
NOTE: Measure several times around circumference

and note average value. Permitted disc play of „D“
brake is 0.06 to 0.08” (1.6 to 2.1 mm).
If the above limits are exceeded, use suitable first outer
disc to compensate difference.
Outer discs can be supplied in the following thicknesses:

0.08”; 0.10”; 0.12” (2.00 mm; 2.50 mm; 3.00 mm).
008966
2-234
Ecomat HP 500 / HP 590 Notes
2-235

5HP500-590 4139 - 751 - 627d

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5HP500-590 4139 - 751 - 627d

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REPAIR MANUAL

4139 751 627d

Chapter Contents Page

1. Placing transmission in assembly stand and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2. Removal, installation, disassembly and assembly of retarder accumulator . . . . . . . . . . . . 2-4

3. Removal, installation, disassembly and assembly of oil cooler . . . . . . . . . . . . . . . . . . . . . . 2-12

5. Removal, installation, disassembly and assembly of converter . . . . . . . . . . . . . . . . . . . . . . 2-23

Chapter Contents Page

6. Removal and installation of cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

7. Removal and installation of oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

8. Removal and installation of inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

10. Removal and installation of retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

11. Removal, installation, disassembly and assembly of output cover . . . . . . . . . . . . . . . . . . . 2-108

Chapter Contents Page

12. Removal and installation of mechanical transmission section . . . . . . . . . . . . . . . . . . . . . . 2-141

13. Removal, installation, disassembly and assembly of control unit . . . . . . . . . . . . . . . . . . . . 2-173

14. Removal and installation of D brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-230

2. Specified equipment, e.g. specialized tools

3. Genuine ZF spares, to our latest specifications

Layout of the service manual

Important work safety notice:

The following safety instructions appear in this manual:

NOTE: Refers to special processes, techniques, data, use

CAUTION This is used when incorrect, unprofessional

! DANGER This is used when lack of care could lead to

Always follow the working steps as described in the text.

Sectional view of the ECOMAT 4-speed version

1 Input 15 Brake “F”

Sectional view of the ECOMAT 5-speed version

1 Input 14 Inductive sensor “output”

Tightening torques for bolts and nuts from ZFN 148

Tighten screws using a calibrated signal or pointer-type torque wrench.

Metric coarse pitch thread Metric fine pitch thread

Size Tightening torque Size Tightening torque

M 4 2.8 4.1 4.8 M 8x1 24 36 43

M 12 79 115 135 M 14 x 1.5 135 200 235

M 18 280 390 460 M 18 x 2 290 420 490

M 24 670 960 1100 M 24 x 1.5 760 1100 1250

M 27 x 2 1050 1500 1800

Edition: August 1991

Description Data Measuring device Remarks

01. Installation dimension of 2.81 ± 0.02" Depth gauge Installation dimension

06. Tightening torque of cap Torque wrench

Description Data Measuring device Remarks

Description Data Measuring device Remarks

17. Tightening torque of M6 3.7 to 5.6 ft-lbs Torque wrench

18. Tightening torque of M6 5 ft-lbs Torque wrench

Description Data Measuring device Remarks

29. Tightening torque of M8 26 ft-lbs (35 Nm) Torque wrench

Description Data Measuring device Remarks

38. Tightening torque of 60 to 74 ft-lbs Torque wrench

Description Data Measuring device Remarks

Other transmission data

43. Tightening torque of approx. 60 ft-lbs Experience

0732 041 934 Control insert - 13.50 0.055" 0.4" 2.21"

0732 041 718 Control insert - 14.50 0.095" 0.57" 2.42"

0732 041 719 Control insert - 10.50 0.138" 0.90" 2.57"

0732 042 113 Control insert - 17.50 0.110" 0.61" 2.93"

0732 042 114 Control insert - 11.50 0.118" 0.90" 2.79"

0732 041 125 Control insert - 4.50 0.098" 0.91" 0.89"

0732 040 786 Control insert - 14.50 0.098" 0.69" 2.65"

0732 041 269 Clutch carrier 28.50 0.070" 0.45" 3.43"